Ford - Explorer 2wd - Workshop Manual - 2007 - 2007

Factory Workshop Manual Make Ford Model Explorer 2wd Engine and year V6-4.0L VIN K (2007) 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 View 151-17 (Right Rear, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 12 View 151-29 (Rear End) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 13 Parking Assist Control Module: Diagrams C4014 C4226 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 14 Parking Assist Control Module: Service and Repair PARKING AID MODULE Removal and Installation 1. Disconnect the parking aid module bumper harness from the body harness. 2. Remove the rear bumper cover. 3. Remove the 4 insulator-to-bumper cover nuts and the insulator from the bumper cover. 4. Disconnect the parking aid module bumper harness from the parking aid module. 5. Remove the 2 parking aid module bracket bolts. 6. Remove the parking module bracket assembly. 7. Release the module tabs from the bracket and remove the module. 8. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Pedal Positioning Module > Component Information > Description and Operation Pedal Positioning Module: Description and Operation Adjustable Pedals Using the adjustable pedal switch located on the instrument panel, the driver can adjust the brake and accelerator pedals for a more comfortable driving position. For removal and installation of the adjustable pedals, refer to Brake Pedal and Bracket. Adjustable Pedal Operation The adjustable pedals with or without memory feature are operational with the ignition switch in the ON or OFF position. The pedals are adjusted forward or rearward using the adjustable pedal switch. Memory Adjustable Pedal Operation The adjustable pedals with memory feature is controlled by using the memory switches or the remote keyless entry (RKE) transmitter. The exterior mirror and power driver seat positions are also stored and recalled with the power adjustable pedal positions. The system can store 3 memory settings. Driver Seat Module (DSM) The DSM controls the memory adjustable pedals. The DSM constantly monitors the systems under its control and records concerns in the form of diagnostic trouble codes (DTCs). A DTC can be retrieved with the scan tool through the data link connector (DLC). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations View 151-19 (Driver Seat) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 22 Memory Positioning Module: Diagrams C341A C341B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 23 C341C Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 24 Memory Positioning Module: Description and Operation Memory Adjustable Pedal Operation The adjustable pedals with memory feature is controlled by using the memory switches or the remote keyless entry (RKE) transmitter. The exterior mirror and power driver seat positions are also stored and recalled with the power adjustable pedal positions. The system can store 3 memory settings. Driver Seat Module (DSM) The DSM controls the memory adjustable pedals. The DSM constantly monitors the systems under its control and records concerns in the form of diagnostic trouble codes (DTCs). A DTC can be retrieved with the scan tool through the data link connector (DLC). Memory Adjustable Pedal Operation The adjustable pedals with memory feature is controlled by using the memory switches or the remote keyless entry (RKE) transmitter. The exterior mirror and power driver seat positions are also stored and recalled with the power adjustable pedal positions. The system can store 3 memory settings. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Module > Component Information > Description and Operation Pedal Positioning Module: Description and Operation Adjustable Pedals Using the adjustable pedal switch located on the instrument panel, the driver can adjust the brake and accelerator pedals for a more comfortable driving position. For removal and installation of the adjustable pedals, refer to Brake Pedal and Bracket. Adjustable Pedal Operation The adjustable pedals with or without memory feature are operational with the ignition switch in the ON or OFF position. The pedals are adjusted forward or rearward using the adjustable pedal switch. Memory Adjustable Pedal Operation The adjustable pedals with memory feature is controlled by using the memory switches or the remote keyless entry (RKE) transmitter. The exterior mirror and power driver seat positions are also stored and recalled with the power adjustable pedal positions. The system can store 3 memory settings. Driver Seat Module (DSM) The DSM controls the memory adjustable pedals. The DSM constantly monitors the systems under its control and records concerns in the form of diagnostic trouble codes (DTCs). A DTC can be retrieved with the scan tool through the data link connector (DLC). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Locations View 151-15 (Left Rear, (1 0f 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Diagrams > Third Row Folding Seat Relay, Left C4183 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Diagrams > Third Row Folding Seat Relay, Left > Page 33 C4184 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 36 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Auxiliary Step / Running Board Module > Component Information > Service and Repair Auxiliary Step / Running Board Module: Service and Repair RETRACTABLE RUNNING BOARD MODULE Removal and Installation 1. Remove the RH C-pillar trim panel. 2. Disconnect the retractable running board module electrical connectors. 3. Remove the 3 screws and the retractable running board module assembly. - To install, tighten to 7 Nm (62 lb-in). 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations View 151-26 (Roof) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 43 C921 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations > Page 47 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations View 151-2 (Engine Compartment - 4.0L, (2 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 52 C155 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 53 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System (ABS) Module Material Removal and Installation WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in personal injury. 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: Electronic modules are sensitive to electrical charges. The ABS module can be damaged if exposed to these charges. NOTE: When installing a new ABS module, it must be configured (using vehicle as-built data) and calibrated. Follow the scan tool directions for the calibration procedures. For module configuration, refer to Information Bus. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 54 1. Remove the hydraulic control unit (HCU). 2. CAUTION: Make sure that the ABS module is properly seated to the HCU and that the torque of the ABS module screws is correct, or damage to the components can occur. Remove the 4 screws and the ABS module. ^ To install, tighten to 2 Nm (18 inch lbs.). 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations View 151-11 (behind Dash Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations > Page 58 C239 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Motor Relay 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Motor Relay 1 > Page 64 View 151-27 (Front HVAC) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 65 C2017 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay 1 > Page 68 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 72 Compressor Clutch Relay: Description and Operation AIR CONDITIONING (A/C) CLUTCH RELAY (A/CCR) NOTE: The PCM PIDs WAC and wide open throttle air conditioning cutoff fault (WACF) are used to monitor the A/CCR output. The A/CCR is wired normally open. There is no direct electrical connection between the A/C switch or electronic automatic temperature control (EATC) module and the A/C clutch. The PCM receives a signal indicating that A/C is requested. For some applications, this message is sent through the communications network. When A/C is requested, the PCM checks other A/C related inputs that are available, such as A/C pressure switch and A/C cycling switch. If these inputs indicate A/C operation is OK, and the engine conditions are OK (coolant temperature, engine RPM, throttle position), the PCM grounds the A/CCR output, closing the relay contacts and sending voltage to the A/CCR. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 73 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Page 77 Control Module HVAC: Diagrams C228A C228B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > System Relay, HVAC > Component Information > Locations View 151-15 (Left Rear, (1 0f 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > System Relay, HVAC > Component Information > Locations > Page 81 C3023 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > System Relay, HVAC > Component Information > Locations > Page 82 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > Customer Interest for Fuel Distance/Mileage Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets Fuel Distance/Mileage Module: Customer Interest Instruments - Trip Odometers/Fuel Economy Resets TSB 09-21-7 11/02/09 TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS UNINTENTIONALLY FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally. This condition may occur if there is an intermittent electrical connection on the power feed to the cluster or if the reset button on the 3-button message center assembly is momentarily touched. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. With the key in the On position, display the trip odometer mileage. 2. Start the vehicle. 3. Cycle the key back Off and restart the vehicle. 4. Verify whether the trip mileage reset or not. 5. If not, proceed to Step 10. 6. If it reset, turn the key Off and remove the key from the ignition. 7. Activate the emergency flashers. 8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal fuse and wiring diagnostics to correct the power feed circuit. 9. Verify repair and proceed to Step 10. 10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release 63.07 and higher. This new calibration is not included in the VCM 2009.9 DVD. Calibration files may also be obtained at the website. NOTE REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT RESOLVE THIS ISSUE. 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 092107A 2006-2010 Explorer, 0.3 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > Customer Interest for Fuel Distance/Mileage Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 92 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Distance/Mileage Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets Fuel Distance/Mileage Module: All Technical Service Bulletins Instruments - Trip Odometers/Fuel Economy Resets TSB 09-21-7 11/02/09 TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS UNINTENTIONALLY FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally. This condition may occur if there is an intermittent electrical connection on the power feed to the cluster or if the reset button on the 3-button message center assembly is momentarily touched. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. With the key in the On position, display the trip odometer mileage. 2. Start the vehicle. 3. Cycle the key back Off and restart the vehicle. 4. Verify whether the trip mileage reset or not. 5. If not, proceed to Step 10. 6. If it reset, turn the key Off and remove the key from the ignition. 7. Activate the emergency flashers. 8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal fuse and wiring diagnostics to correct the power feed circuit. 9. Verify repair and proceed to Step 10. 10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release 63.07 and higher. This new calibration is not included in the VCM 2009.9 DVD. Calibration files may also be obtained at the website. NOTE REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT RESOLVE THIS ISSUE. 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 092107A 2006-2010 Explorer, 0.3 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Distance/Mileage Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 98 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets Instrument Panel Control Module: Customer Interest Instruments - Trip Odometers/Fuel Economy Resets TSB 09-21-7 11/02/09 TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS UNINTENTIONALLY FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally. This condition may occur if there is an intermittent electrical connection on the power feed to the cluster or if the reset button on the 3-button message center assembly is momentarily touched. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. With the key in the On position, display the trip odometer mileage. 2. Start the vehicle. 3. Cycle the key back Off and restart the vehicle. 4. Verify whether the trip mileage reset or not. 5. If not, proceed to Step 10. 6. If it reset, turn the key Off and remove the key from the ignition. 7. Activate the emergency flashers. 8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal fuse and wiring diagnostics to correct the power feed circuit. 9. Verify repair and proceed to Step 10. 10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release 63.07 and higher. This new calibration is not included in the VCM 2009.9 DVD. Calibration files may also be obtained at the website. NOTE REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT RESOLVE THIS ISSUE. 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 092107A 2006-2010 Explorer, 0.3 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 107 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets Instrument Panel Control Module: All Technical Service Bulletins Instruments - Trip Odometers/Fuel Economy Resets TSB 09-21-7 11/02/09 TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS UNINTENTIONALLY FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally. This condition may occur if there is an intermittent electrical connection on the power feed to the cluster or if the reset button on the 3-button message center assembly is momentarily touched. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. With the key in the On position, display the trip odometer mileage. 2. Start the vehicle. 3. Cycle the key back Off and restart the vehicle. 4. Verify whether the trip mileage reset or not. 5. If not, proceed to Step 10. 6. If it reset, turn the key Off and remove the key from the ignition. 7. Activate the emergency flashers. 8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal fuse and wiring diagnostics to correct the power feed circuit. 9. Verify repair and proceed to Step 10. 10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release 63.07 and higher. This new calibration is not included in the VCM 2009.9 DVD. Calibration files may also be obtained at the website. NOTE REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT RESOLVE THIS ISSUE. 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 092107A 2006-2010 Explorer, 0.3 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 113 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 118 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 122 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 126 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 137 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Relay Box: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 142 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 143 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 144 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 145 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 146 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 147 Battery Junction Box (BJB) / Power Distribution Box - Early Production Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 148 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 149 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 150 Battery Junction Box (BJB) / Power Distribution Box - Late Production Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 151 Relay Box: Locations Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) Relay Box: Diagrams Battery Junction Box (BJB) C1035A C1035B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 154 Relay Box: Diagrams Smart Junction Box (SJB) C2280A Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 155 C2280B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 156 C2280C Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 157 C2280D Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 158 C2280E Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 161 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 162 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 163 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 164 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 165 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 166 Battery Junction Box (BJB) / Power Distribution Box - Early Production Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 167 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 168 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 169 Battery Junction Box (BJB) / Power Distribution Box - Late Production Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 170 Relay Box: Application and ID Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Specifications Torque Specifications Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) Body Control Module: Service and Repair Driver Seat Module (DSM) DRIVER SEAT MODULE (DSM) Special Tool(s) Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 178 Removal and Installation CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: Prior to the removal of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new DSM after installation. 1. Remove the driver seat. 2. Remove the 2 DSM screws. 3. Disconnect the electrical connectors and remove the DSM. 4. NOTE: Once the module is installed it is necessary to download the module configuration information from the scan tool into the new module. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 179 Body Control Module: Service and Repair Smart Junction Box (Sjb) SMART JUNCTION BOX (SJB) Special Tool(s) Special Tool(s) Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 180 Part 2 Removal NOTE: - The steps included in the SJB removal and installation procedure are critical to restoring the vehicle security and tire pressure monitoring systems to normal operation. A new SJB is delivered in manufacturing mode with 6 pre-set diagnostic trouble codes (DTCs) related to the tire pressure monitoring system. The presence of these DTCs requires the installation procedures be followed in order to clear the DTCs and enable normal SJB operations. - Prior to the removal of the SJB, it is necessary to upload the module configuration information to the diagnostic tool. This information must be downloaded to the new SJB after installation. 1. Remove the driver door scuff plate. 2. Position the LH door opening weather seal aside. 3. NOTE: While pulling the trim panel rearward, pull the hood release lever rearward in order for the release lever to slide through the trim panel. Remove the pushpin and the cowl side trim panel. 4. Remove the 2 bolts and the parking brake release handle. 5. Disconnect the parking brake switch electrical connector. 6. Release the hood release cable pushpin from the parking brake control bracket. 7. Release the harness clip from the parking brake cable housing. 8. NOTE: Rotating the parking brake control counterclockwise allows enough access to clear the instrument panel reinforcement. Remove the 3 bolts and position the parking brake control assembly under the brake pedal. 9. CAUTION: The lower side of the headlight switch bezel includes 2 tabs that slide down onto the instrument panel and may be broken if any prying force is exerted in the lower area of the bezel. Using a suitable tool, pry the mid-to-upper side of the headlight switch bezel away from the instrument panel, disconnect the 2 electrical connectors and position the bezel assembly aside. 10. If necessary, push the LH instrument panel side finish panel out and position it aside. 11. Through the headlight switch bezel opening, remove the 2 SJB bolts. 12. From under the instrument panel, remove the third SJB bolt. 13. NOTE: The SJB electrical connector levers must click into a fully released position before they can be removed and must click into a fully closed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 181 (connected) position when installing. Pull the SJB down out of the 2 locating pins, disconnect the 5 electrical connectors and remove the SJB. Installation NOTE: When a new SJB is installed, all customer RKE transmitters may be required to program the RKE transmitters to the new SJB. 1. NOTE: The SJB electrical connector levers must click into a fully released position before they can be removed and must click into a fully closed (connected) position when installing. Position the SJB into the 2 locating pins and connect the 5 electrical connectors. 2. From under the instrument panel, install the SJB bolt. 3. Through the headlight switch bezel opening, install the 2 SJB bolts. 4. If necessary, install the LH instrument panel side finish panel. 5. Connect the 2 electrical connectors and install the headlight switch bezel assembly into the instrument panel. 6. Position the parking brake control assembly and install the 3 bolts. - Tighten to 20 Nm (15 lb-ft). 7. Install the harness clip on the parking brake cable housing. 8. Install the hood release cable pushpin into the parking brake control bracket. 9. Connect the parking brake switch electrical connector. 10. Position the parking brake release handle and install the 2 bolts. 11. Position the hood release lever assembly and install the bolt. 12. NOTE: While installing the trim panel, pull the hood release lever rearward in order for the release lever to slide through the trim panel. Position the cowl side trim panel and install the pushpin. 13. Position the LH door opening weather seal. 14. Install the driver door scuff plate. 15. NOTE: When successful, this step provides the calibration necessary for SJB operation and clears DTC B2477. The clearing of the DTC indicates the calibration data has been successfully downloaded to the SJB. Download the SJB configuration information from the diagnostic tool to the SJB. 16. NOTE: When successful, this step clears DTCs B2868, B2869, B2870 and B2871. The clearing of these DTCs indicates the SJB has recognized the tire pressure sensors during the training procedure. Train the tire pressure sensors. 17. Clear the DTCs. 18. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode, and to be sure there are no other concerns with the newly programmed SJB. Carry out the SJB on-demand self-test. 19. NOTE: If the module configuration upload/download is successful, then the RKE transmitters do not need to be reprogrammed to the vehicle. However, if the module configuration upload/download is unsuccessful and as-built data must be used to configure the module, then ALL of the customer's RKE transmitters must be reprogrammed to the vehicle. Program the RKE transmitters to the new SJB (if necessary). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation Electronic Throttle Control Module: Description and Operation TORQUE BASED ELECTRONIC THROTTLE CONTROL (ETC) Overview The torque based ETC is a hardware and software strategy that delivers an engine output torque (via throttle angle) based on driver demand (pedal position). It uses an electronic throttle body, the powertrain control module (PCM), and an accelerator pedal assembly to control the throttle opening and engine torque. The ETC system replaces the standard cable operated accelerator pedal, idle air control (IAC) valve, 3-wire throttle position (TP) sensor, and mechanical throttle body. Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque during shifts, and by calculating this desired torque, the system prevents engine lugging (low RPM and low manifold vacuum) while still delivering the performance and torque requested by the driver. It also enables many fuel economy/emission improvement technologies such as variable camshaft timing (VCT) (deliver same torque during transitions). Torque based ETC also results in less intrusive vehicle and engine speed limiting, along with smoother traction control. Other benefits of ETC are: eliminate cruise control actuators - eliminate idle air control (IAC) valve - better airflow range - packaging (no cable) - more responsive powertrain at altitude and improved shift quality It should be noted that the ETC system illuminates a powertrain malfunction indicator (wrench) on the instrument cluster when a concern is present. Concerns are accompanied by diagnostic trouble codes (DTCs) and may also illuminate the malfunction indicator lamp (MIL). Electronic Throttle Body (ETB) The ETB has the following characteristics: 1. The throttle actuator control (TAC) motor is a DC motor controlled by the PCM (requires 2-wires). The gear ratio from the motor to the throttle plate shaft is 17:1. 2. There are 2 designs: parallel and in-series. The parallel design has the motor under the bore parallel to the plate shaft. The motor housing is integrated into the main housing. The in-series design has a separate motor housing. 3. Two springs are used: one is used to close the throttle (main spring) and the other is in a plunger assembly that results in a default angle when no power is applied. This is for limp home reasons (the force of the plunger spring is 2 times stronger than the main spring). The default angle is usually set to result in a top vehicle speed of 48 km/h (30 mph). Typically this throttle angle is 7 to 8 degrees from the hard-stop angle. 4. The closed throttle plate hard stop is used to prevent the throttle from binding in the bore (~0.75 degree). This hard stop setting is not adjustable and is set to result in less airflow than the minimum engine airflow required at idle. 5. Unlike cable operated throttle bodies, the intent for the ETB is not to have a hole in the throttle plate or to use plate sealant. The hole is not required in the ETB because the required idle airflow is provided by the plate angle in the throttle body assembly. This plate angle controls idle, idle quality, and eliminates the need for an IAC valve. 6. The TP sensor has 2 signal circuits in the sensor for redundancy. The redundant throttle position signals are required for increased monitoring reasons. The first TP signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). During normal operation the negative slope TP signal (TP1) is used by the control strategy as the indication of throttle position. The TP sensor assembly requires 4 circuits. 5-volt reference voltage - Signal return (ground) - TP1 voltage with negative voltage slope (5-0 volts) - TP2 voltage with positive voltage slope (0-5 volts) Accelerator Pedal Position (APP) Sensors Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 185 Electronic Throttle Body (ETB) And Accelerator Pedal Assembly The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1. There are 3 pedal position signals required for system monitoring. APP1 has a negative slope (increasing angle, decreasing voltage) and APP2 and APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. 2. There are 2 VREF circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. 2 reference voltage circuits (5 volts) - 2 signal return (ground) circuits - APP1 voltage with negative voltage slope (5-0 volts) - APP2 voltage with positive voltage slope (0-5 volts) - APP3 voltage with positive voltage slope (0-5 volts) 3. The pedal position signal is convened to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. 4. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. A value is substituted for an incorrect signal if 2 of the 3 signals are incorrect. Electronic Throttle Control (ETC) System Strategy Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 186 ETC System The torque based ETC strategy was developed to improve fuel economy and to accommodate variable camshaft timing (VCT). This is possible by not coupling the throttle angle to the driver pedal position. Uncoupling the throttle angle (produce engine torque) from the pedal position (driver demand) allows the powertrain control strategy to optimize fuel control and transmission shift schedules while delivering the requested wheel torque. The ETC monitor system is distributed across 2 processors within the PCM: the main powertrain control processor unit (CPU) and a monitoring processor called an enhanced-quizzer (E-Quizzer) processor. The primary monitoring function is carried out by the independent plausibility check (IPC) software, which resides on the main processor. It is responsible for determining the driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the generated torque exceeds driver demand by a specified amount, the IPC takes appropriate corrective action. ETC System Failure Mode And Effects Management (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 187 ETC System Failure Mode And Effects Management (Part 2) Since the IPC and the main controller share the same processor, they are subject to a number of potential common failure modes. The E-Quizzer processor was added to redundantly monitor selected PCM inputs and to act as an intelligent watchdog and monitor the performance of the IPC and the main processor. If it determines that the IPC function is impaired in any way, it takes appropriate failure mode and effects management (FMEM) actions. Electronic Throttle Monitor Operation: Electronic Throttle Monitor Operation (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 188 Electronic Throttle Monitor Operation (Part 2) Accelerator and Throttle Position (TP) Sensor Inputs Accelerator Pedal Position (APP) Sensor Check: Accelerator Pedal Position (APP) Sensor Check Throttle Position (TP) Sensor Check: Throttle Position (TP) Sensor Check Throttle Plate Position Controller (TPPC) Outputs Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 189 Throttle Plate Controller Check Operation The purpose of the TPPC is to maintain the throttle position at the desired throttle angle. It is a separate chip embedded in the PCM. The desired angle is communicated from the main CPU via a 312.5 Hz duty cycle (DC) signal. The TPPC interprets the duty cycle signal as follows: Less than 4% - Out of range, limp home default position. - Greater than or equal to 4% but less than 6% - Commanded default position, closed. - Greater than or equal to 6% but less than 7% - Commanded default position. Used for key ON, engine OFF. - Greater than or equal to 7% but less than 8% - Enable ice breaker mode. Used to clear potential ice buildup in the throttle body. - Greater than or equal to 8% but less than 10% - Closed against hard-stop. Used to learn zero throttle angle position (hard stop) after key-up. - Greater than or equal to 10% but less than or equal to 92% - Normal operation, between 0 degrees (hard stop) and 82 degrees, 10% duty cycle equals 0 degrees throttle angle, 92% duty cycle equals 82 degrees throttle angle. - Greater than 92% but less than or equal to 96% - Wide open throttle, 82 to 86 degrees throttle angle. - Greater than 96% but less than or equal to 100% - Out of range, limp home default position. The desired angle is relative to the hard-stop angle. The hard stop angle is learned during each key-up process before the main CPU requests the throttle plate be closed against the hard stop. The output of the TPPC is a voltage request to the H driver (also in PCM). The H driver is capable of positive or negative voltage to the electronic throttle body motor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start Engine Control Module: Customer Interest Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start TSB 08-18-2 09/15/08 MIL ON - P0506 AND/OR P0505 - HESITATION/LOSS OF RPM/DIFFICULTY STARTING/LOW IDLE RPM FORD: 2005-2007 Crown Victoria 2006 Mustang, Mustang 2004-2006 F-150, F-150 2005-2006 E-350, E-450, F-Super Duty 2006 F-53 Motorhome Chassis 2006-2007 Explorer Sport Trac, Explorer LINCOLN: 2005-2007 Town Car 2006 Mark LT MERCURY: 2005-2007 Grand Marquis 2006-2007 Mountaineer, Mountaineer This article supersedes TSB(s) 08-5-13, 07-23-12 and 06-25-8 to update the Service Procedure. ISSUE Some 2004-2006 4.6L and 5.4L F-150 (excluding F-150 Heritage), 2006 5.4L Mark LT, 2005-2006 6.8L E-350 / E-450, 2005-2006 6.8L F-Super Duty (F-250 to F-550), 2006 6.8L F-53 Motorhome Chassis, 2006-2007 4.0L Explorer 4 dr, 2007 4.0L Explorer Sport Trac, 2006-2007 4.0L Mountaineer, 2006 4.0L Mustang, 2006 - 2007 4.6L 3V Explorer / Explorer Sport Trac / Mountaineer, 2006 4.6L 3V Mustang, and 2005-2007 Crown Vic / Grand Marquis / Towncar vehicles may exhibit one or more of the following symptoms: drive-away hesitation, loss of RPM on deceleration, difficulty starting, and/or idle RPM less than desired. Malfunction indicator lamp (MIL) may be illuminated with diagnostic trouble codes (DTCs) P0506 and/or P0505. These conditions may appear after battery disconnect, dead battery condition, or keep alive memory (KAM) reset. The symptoms may be due to engine deposits in the throttle leading to air[low less than desired. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 53.9 and higher or 54.1 and higher. This new calibration is not included in the VCM 2008.1 DVD. Calibration files may also be obtained at the website. The calibration contains a sludge compensation strategy for the throttle body. 2. Turn the key off to re-initialize the PCM. This will allow the sludge compensation strategy to learn. 3. With the vehicle in park or neutral and A/C off, start vehicle and allow engine to reach normal operating temperature(greater than 170 °F (77 °C) coolant temperature). Run an additional 5 minutes to allow sufficient learning time. 4. While the engine is running, using IDS datalogger or equivalent, check the PID value of ETC_TRIM. a. If ETC_TRIM value is 3.5 degrees, and/or DTC PuSE is present, then replace the electronic throttle body (ETB), following Workshop Manual (WSM), Section 303-04B. b. If ETC_TRIM value is less than 3.5 degrees and DTC PuSE is not present, but driveability concerns persist, the ETB is not the likely cause of the concern and replacement is not necessary. Continue with normal PC/ED diagnostics. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start > Page 198 NOTE VEHICLES EQUIPPED WITH A PCM AND TCM REQUIRE COORDINATED REPROGRAMMING. THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS OUTLINED BY THE IDS. FAILURE TO FOLLOW THE KEY CYCLE PROCEDURE WITHOUT WAITING FOR THE IDS PROMPTS, WILL CAUSE THE COORDINATED REPROGRAMMING TO FAIL. THE PCM WILL BE UPDATED BUT THE 1CM WILL NOT BE UPDATED AND NEW FILES WILL NOT BE INSTALLED. IT IS CRITICAL TO FOLLOW THE IDS PROMPTS. SOME VEHICLES MAY REQUIRE SEVERAL DAYS OF DRIVING FOR THE TRANSMISSION TO FULLY ADAPT. REPROGRAMMING CONCERNS/ERRORS MAY BE CAUSED BY THE DATA LINK CONNECTOR (DLC) OR VEHICLE COMMUNICATION MODULE (VCM) BECOMING DISCONNECTED, LOW BATTERIES ON THE INTEGRATED DIAGNOSTIC SYSTEM (IDS) OR THE IDS GOING INTO ANY TYPE OF SLEEP MODE, OR LOW VEHICLE BATTERY VOLTAGE. IF THERE WAS AN INTERRUPTION DURING REPROGRAMMING, MAKE SURE THE ORIGINAL IDS SESSION THAT WAS CREATED FOR THE VEHICLE IS NOT DELETED. IF THE ORIGINAL VEHICLE SESSION IS NOT USED OR DELETED BEFORE THE MODULES ARE COMPLETELY REPROGRAMMED, FURTHER REPROGRAMMING ERRORS CAN OCCUR. THE MODULE RECOVERY PROCEDURE IS NO LONGER AVAILABLE AND IT IS CRITICAL THAT MODULE SWAPPING IS NOT PERFORMED FROM VEHICLE TO VEHICLE. TO REGAIN COMMUNICATION WITH A MODULE THAT HAS BEEN ERASED DURING REPROGRAMMING, RESUME THE ORIGINAL SESSION ONCE THE IDS IS RE-BOOTED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081802A 2004-2006 F-150 0.4 Hr. 4.6L/5.4L, 2006 Mark LT, Econoline 350/450 6.8L 2005-2006 F-Super Duty 6.8L, 2006-2007 Explorer/Mountaineer 4.0L, 2007 Explorer Sport Trac 4.0L, 2006 Mustang 4.OL, 2005-2007 Crown Victoria, Town Car, Grand Marquis: Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Authorization Decal NOT Necessary. (Do Not Use With 9926A, 12650D) 081802A 2006-2007 1.0 Hr. Explorer/Mountaineer 4.6L, 2007 Explorer Sport Trac 4.6L: Check For DICs And Reprogram The PCM And 1CM, Includes Time To Monitor ETC_Trim Value, Authorization Decal NOT Necessary. (Do Not Use With 9926A, 12650D) 081802B 2004-2006 F-150 5.4L, 0.9 Hr. 2006 Mark LT: Check For DTCs And Reprogram The PCM, Includes Time To Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start > Page 199 Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2004-2006 F-150 4.6L: 0.8 Hr. Check For DTCs And Reprogram The PCM Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2005-2006 Econoline 6.8L: 1.1 Hrs. Check For DTCs And Reprogram The PCM Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2005-2006 F-Super Duty 0.9 Hr. 6.8L: Check For DTCs And Reprogram The PCM Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2006-2007 Explorer, 1.4 Hrs. Mountaineer 2007 Explorer Sport Trac 4.6L: Check For DTCs And Reprogram The PCM And TCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2006-2007 Explorer, 0.8 Hr. Mountaineer 2007 Explorer Sport Trac 4.0L: Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2005-2007 Crown Victoria, 0.8 Hr. Town Car, Grand Marquis: Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start > Page 200 Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2006 Mustang 4.0L/4.6L: 0.8 Hr. Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start TSB 08-18-2 09/15/08 MIL ON - P0506 AND/OR P0505 - HESITATION/LOSS OF RPM/DIFFICULTY STARTING/LOW IDLE RPM FORD: 2005-2007 Crown Victoria 2006 Mustang, Mustang 2004-2006 F-150, F-150 2005-2006 E-350, E-450, F-Super Duty 2006 F-53 Motorhome Chassis 2006-2007 Explorer Sport Trac, Explorer LINCOLN: 2005-2007 Town Car 2006 Mark LT MERCURY: 2005-2007 Grand Marquis 2006-2007 Mountaineer, Mountaineer This article supersedes TSB(s) 08-5-13, 07-23-12 and 06-25-8 to update the Service Procedure. ISSUE Some 2004-2006 4.6L and 5.4L F-150 (excluding F-150 Heritage), 2006 5.4L Mark LT, 2005-2006 6.8L E-350 / E-450, 2005-2006 6.8L F-Super Duty (F-250 to F-550), 2006 6.8L F-53 Motorhome Chassis, 2006-2007 4.0L Explorer 4 dr, 2007 4.0L Explorer Sport Trac, 2006-2007 4.0L Mountaineer, 2006 4.0L Mustang, 2006 - 2007 4.6L 3V Explorer / Explorer Sport Trac / Mountaineer, 2006 4.6L 3V Mustang, and 2005-2007 Crown Vic / Grand Marquis / Towncar vehicles may exhibit one or more of the following symptoms: drive-away hesitation, loss of RPM on deceleration, difficulty starting, and/or idle RPM less than desired. Malfunction indicator lamp (MIL) may be illuminated with diagnostic trouble codes (DTCs) P0506 and/or P0505. These conditions may appear after battery disconnect, dead battery condition, or keep alive memory (KAM) reset. The symptoms may be due to engine deposits in the throttle leading to air[low less than desired. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 53.9 and higher or 54.1 and higher. This new calibration is not included in the VCM 2008.1 DVD. Calibration files may also be obtained at the website. The calibration contains a sludge compensation strategy for the throttle body. 2. Turn the key off to re-initialize the PCM. This will allow the sludge compensation strategy to learn. 3. With the vehicle in park or neutral and A/C off, start vehicle and allow engine to reach normal operating temperature(greater than 170 °F (77 °C) coolant temperature). Run an additional 5 minutes to allow sufficient learning time. 4. While the engine is running, using IDS datalogger or equivalent, check the PID value of ETC_TRIM. a. If ETC_TRIM value is 3.5 degrees, and/or DTC PuSE is present, then replace the electronic throttle body (ETB), following Workshop Manual (WSM), Section 303-04B. b. If ETC_TRIM value is less than 3.5 degrees and DTC PuSE is not present, but driveability concerns persist, the ETB is not the likely cause of the concern and replacement is not necessary. Continue with normal PC/ED diagnostics. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start > Page 206 NOTE VEHICLES EQUIPPED WITH A PCM AND TCM REQUIRE COORDINATED REPROGRAMMING. THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS OUTLINED BY THE IDS. FAILURE TO FOLLOW THE KEY CYCLE PROCEDURE WITHOUT WAITING FOR THE IDS PROMPTS, WILL CAUSE THE COORDINATED REPROGRAMMING TO FAIL. THE PCM WILL BE UPDATED BUT THE 1CM WILL NOT BE UPDATED AND NEW FILES WILL NOT BE INSTALLED. IT IS CRITICAL TO FOLLOW THE IDS PROMPTS. SOME VEHICLES MAY REQUIRE SEVERAL DAYS OF DRIVING FOR THE TRANSMISSION TO FULLY ADAPT. REPROGRAMMING CONCERNS/ERRORS MAY BE CAUSED BY THE DATA LINK CONNECTOR (DLC) OR VEHICLE COMMUNICATION MODULE (VCM) BECOMING DISCONNECTED, LOW BATTERIES ON THE INTEGRATED DIAGNOSTIC SYSTEM (IDS) OR THE IDS GOING INTO ANY TYPE OF SLEEP MODE, OR LOW VEHICLE BATTERY VOLTAGE. IF THERE WAS AN INTERRUPTION DURING REPROGRAMMING, MAKE SURE THE ORIGINAL IDS SESSION THAT WAS CREATED FOR THE VEHICLE IS NOT DELETED. IF THE ORIGINAL VEHICLE SESSION IS NOT USED OR DELETED BEFORE THE MODULES ARE COMPLETELY REPROGRAMMED, FURTHER REPROGRAMMING ERRORS CAN OCCUR. THE MODULE RECOVERY PROCEDURE IS NO LONGER AVAILABLE AND IT IS CRITICAL THAT MODULE SWAPPING IS NOT PERFORMED FROM VEHICLE TO VEHICLE. TO REGAIN COMMUNICATION WITH A MODULE THAT HAS BEEN ERASED DURING REPROGRAMMING, RESUME THE ORIGINAL SESSION ONCE THE IDS IS RE-BOOTED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081802A 2004-2006 F-150 0.4 Hr. 4.6L/5.4L, 2006 Mark LT, Econoline 350/450 6.8L 2005-2006 F-Super Duty 6.8L, 2006-2007 Explorer/Mountaineer 4.0L, 2007 Explorer Sport Trac 4.0L, 2006 Mustang 4.OL, 2005-2007 Crown Victoria, Town Car, Grand Marquis: Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Authorization Decal NOT Necessary. (Do Not Use With 9926A, 12650D) 081802A 2006-2007 1.0 Hr. Explorer/Mountaineer 4.6L, 2007 Explorer Sport Trac 4.6L: Check For DICs And Reprogram The PCM And 1CM, Includes Time To Monitor ETC_Trim Value, Authorization Decal NOT Necessary. (Do Not Use With 9926A, 12650D) 081802B 2004-2006 F-150 5.4L, 0.9 Hr. 2006 Mark LT: Check For DTCs And Reprogram The PCM, Includes Time To Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start > Page 207 Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2004-2006 F-150 4.6L: 0.8 Hr. Check For DTCs And Reprogram The PCM Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2005-2006 Econoline 6.8L: 1.1 Hrs. Check For DTCs And Reprogram The PCM Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2005-2006 F-Super Duty 0.9 Hr. 6.8L: Check For DTCs And Reprogram The PCM Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2006-2007 Explorer, 1.4 Hrs. Mountaineer 2007 Explorer Sport Trac 4.6L: Check For DTCs And Reprogram The PCM And TCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2006-2007 Explorer, 0.8 Hr. Mountaineer 2007 Explorer Sport Trac 4.0L: Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2005-2007 Crown Victoria, 0.8 Hr. Town Car, Grand Marquis: Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start > Page 208 Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2006 Mustang 4.0L/4.6L: 0.8 Hr. Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 Fuel Gauge Sender: All Technical Service Bulletins Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 TSB 06-17-10 09/04/06 MIL ON WITH DTC P0463 OR ERRATIC FUEL GAUGE OPERATION FORD: 2004-2007 Explorer MERCURY: 2004-2007 Mountaineer This article supersedes TSB 06-16-7 to update the Service Procedure. ISSUE Some 2004-2007 Explorer 4dr/Mountaineer vehicles may exhibit the malfunction indicator lamp (MIL) on with diagnostic trouble code (DTC) P0463 or an erratic fuel gauge concern. This could be from sulphur contamination in the fuel, causing an open or high resistance on the fuel sender card. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. For vehicles with customer symptom of erratic fuel gauge operation (with no MIL on), proceed to Step 1a. For vehicles with a customer symptom including the MIL on, proceed to Step 1b. If unable to verify the concern, do not continue with this TSB. a. Follow the appropriate pinpoint test (PPT) for "Fuel Gauge Inaccurate" in Workshop Manual (WSM), Section 413-01. If PPT test results lead to fuel pump module replacement, proceed to Step 2. If PPT test results isolate any problem other than fuel pump module replacement, repair as indicated and do not continue with this TSB. b. Install diagnostic scan tool to retrieve DTCs. If DTC P0463 is retrieved, proceed to Step 2. If DTC P0463 is not retrieved, this TSB does not apply, follow normal WSM diagnostics. 2. Remove fuel tank per WSM, Section 310-01. 3. Remove fuel pump assembly from fuel tank per WSM, Section 310-01. See Figure 1 (Chart) to determine if a kit (contains a fuel level sensor assembly, a wire harness and heat shrink tube) or fuel pump assembly is required for repair. For vehicles that can be serviced with a kit go to Step 4. For vehicles that require fuel pump assembly replacement, go to Step 12. 4. Remove the fuel level sensor assembly (sender card/float rod assembly) from the fuel pump assembly per WSM, Section 310-01. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 214 5. Detach electrical connector from fuel pump housing (Figure 2). 6. Remove wiring harness from the fuel pump assembly flange by depressing the retaining fingers on the harness connector at bottom of flange and pushing upward out of flange (Figure 3). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 215 7. Install new wiring harness by feeding wires through flange hole and inserting harness connector into flange until an audible click is heard. Check for proper retention. 8. Re-attach electrical connector harness to fuel pump housing. Prior to making the connection place one loop in the pump wires away from the convoluted feed tube (Figure 4). 9. Re-attach the signal wire (yellow) on the harness to the signal wire (yellow) on the replacement fuel level sensor assembly per WSM, Section 310-01 (Figure 5). 10. Wrap the ground wire one time around the signal wire and attach the ground wire terminal to the terminal on the fuel level sensor assembly. Check for proper retention. NOTE THE GROUND WIRE MUST BE WRAPPED AROUND THE SIGNAL WIRE, AS DESCRIBED IN STEP 10, TO PREVENT POTENTIAL INTERFERENCE WITH THE FLOAT ROD ARM. 11. Re-attach the fuel level sensor assembly to the fuel pump housing, making sure that both the signal wire and the ground wire are routed through the Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 216 gap between the fuel level sensor assembly and fuel pump bracket. Torque the fastener at the bottom of the fuel level sensor assembly to 1 N.m (9 lb-in). 12. Re-install fuel pump assembly into fuel tank per WSM, Section 310-01. NOTE TAKE CARE NOT TO DAMAGE/BEND FLOAT ROD OR SENDER CARD DURING INSTALLATION OF FUEL PUMP ASSEMBLY. 13. Re-install fuel tank per WSM, Section 310-01. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 061710A 2004-2007 2.9 Hrs. Explorer/Mountaineer: Diagnose And Replace The Fuel Gauge Tank Unit (Do Not Use With 9275D, 9275A, 9002A) DEALER CODING CONDITION BASIC PART NO. CODE 9A299 28 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 222 5. Detach electrical connector from fuel pump housing (Figure 2). 6. Remove wiring harness from the fuel pump assembly flange by depressing the retaining fingers on the harness connector at bottom of flange and pushing upward out of flange (Figure 3). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 223 7. Install new wiring harness by feeding wires through flange hole and inserting harness connector into flange until an audible click is heard. Check for proper retention. 8. Re-attach electrical connector harness to fuel pump housing. Prior to making the connection place one loop in the pump wires away from the convoluted feed tube (Figure 4). 9. Re-attach the signal wire (yellow) on the harness to the signal wire (yellow) on the replacement fuel level sensor assembly per WSM, Section 310-01 (Figure 5). 10. Wrap the ground wire one time around the signal wire and attach the ground wire terminal to the terminal on the fuel level sensor assembly. Check for proper retention. NOTE THE GROUND WIRE MUST BE WRAPPED AROUND THE SIGNAL WIRE, AS DESCRIBED IN STEP 10, TO PREVENT POTENTIAL INTERFERENCE WITH THE FLOAT ROD ARM. 11. Re-attach the fuel level sensor assembly to the fuel pump housing, making sure that both the signal wire and the ground wire are routed through the Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 224 gap between the fuel level sensor assembly and fuel pump bracket. Torque the fastener at the bottom of the fuel level sensor assembly to 1 N.m (9 lb-in). 12. Re-install fuel pump assembly into fuel tank per WSM, Section 310-01. NOTE TAKE CARE NOT TO DAMAGE/BEND FLOAT ROD OR SENDER CARD DURING INSTALLATION OF FUEL PUMP ASSEMBLY. 13. Re-install fuel tank per WSM, Section 310-01. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 061710A 2004-2007 2.9 Hrs. Explorer/Mountaineer: Diagnose And Replace The Fuel Gauge Tank Unit (Do Not Use With 9275D, 9275A, 9002A) DEALER CODING CONDITION BASIC PART NO. CODE 9A299 28 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 225 Engine Control Module: Locations View 151-1 (Engine Compartment - 4.0L, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 226 View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 229 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 230 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 231 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 232 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 233 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 234 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 235 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 236 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 237 Engine Control Module: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 238 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 239 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 240 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 241 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 242 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 243 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 244 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 245 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 246 Engine Control Module: Connector Views C175B (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 247 C175B (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 248 C175E (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 249 C175E (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 250 C175T (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 251 C175T (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) Engine Control Module: Service and Repair Powertrain Control Module (PCM) POWERTRAIN CONTROL MODULE (PCM) Removal All vehicles 1. NOTE: Powertrain control module (PCM) installation DOES NOT require new keys. Retrieve the module configuration. Carry out the module configuration retrieval steps of the Programmable Module Installation procedure. Vehicles equipped with a 4.6L (3V) engine 2. Remove the air cleaner. All vehicles Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) > Page 254 3. Disconnect the RH front wheel speed sensor electrical connector. Remove the nuts and position the A/C tube brackets and wiring harness aside. 4. Disconnect the PCM connectors. 5. Remove the bolts and the PCM. Installation All vehicles 1. Install the PCM and bolts. - Tighten to 10 Nm (89 lb-in). 2. Connect the PCM electrical connectors. 3. Position the wiring harness and the A/C tube brackets and install the nuts. Connect the RH front wheel speed sensor electrical connector. - Tighten to 7 Nm (62 lb-in). Vehicles equipped with a 4.6L (3V) engine 4. Install the air cleaner. All vehicles 5. Restore the module configuration. Carry out the module configuration restore steps of the Programmable Module Installation procedure. 6. Reprogram the passive anti-theft system (PATS). Carry out the Parameter Reset procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) > Page 255 Engine Control Module: Service and Repair Flash Electrically Erasable Programmable Read Only Memory (EEPROM) FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) Description The 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 programmed or flashed repeatedly. As part of the calibration there is an area referred to as the vehicle identification (VID) block. The VID block is programmed when installing a new PCM as described under Programming the VID Block for a Replacement PCM. Failure to carry out this procedure may generate DTCs P1635 or P1639. The VID block in an existing PCM can also be tailored to accommodate various hardware or parameter changes made to the vehicle since production. Failure to carry out this procedure properly may generate DTC P1635, Tire/Axle Ratio out of Acceptable Range. An incorrect tire/axle ratio is one of the main causes for DTC P1639. 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 vehicle identification number (VIN), octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control, and 4-wheel drive electronic shift-on-the-fly (ESOF) versus manual shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported by the VID block is displayed on the scan tool. When changing items in the VID block, the strategy places range limits on certain items such as tire and axle ratio. The number of times the VID block may be reconfigured is limited. When this limit is reached, the scan tool displays a message indicating the need to flash the PCM again to reset the VID block. Programming can be carried out by a local Ford dealer or any non-Ford facility. Refer to the scan tool manufacturer's instruction manual for details. Programming the VID Block for a Replacement PCM A new PCM contains the latest strategy and calibration level for a particular vehicle. However, the VID block is blank and needs programming. There are 2 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 is carried out if the old PCM is capable of communicating. This is done by using a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can then be downloaded to the new PCM after it has been installed. Carry out manual data entry if the old module is damaged or incapable of communicating. Remove and install a new PCM. Using a compatible scan tool, select and carry out the module/parameter programming, referring to the scan tool manufacturer's instruction manual. Make certain that all parameters are included. Failure to properly program tire size in revolutions per mile, (rev/mile equals 63,360 divided by the tire circumference in inches), axle ratio, 4x4/4x2, and/or MSOF/ESOF may result in DTCs P1635 and P1639. 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 and Lincoln Mercury technicians, contact your National Hotline or the Professional Technician Society (PTS) website for As-Built data listed under the Service Publications Index. Non-Ford technicians use the Motorcraft(R) website at www.motorcraft.com. From the Motorcraft(R) homepage, use the search function to find the Module Programming or As-Built Data. For Ford and Lincoln Mercury technicians, check the Programmable Module Installation link on the PTS website for quick Programmable Module data information by vehicle. Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate the vehicle hardware. Refer to Module Reprogramming on the scan tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM needs 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 Module Reprogramming on the scan tool. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 259 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Emission Control Systems > EGR Control Module > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Emission Control Systems > EGR Control Module > Component Information > Locations > Page 264 C1450 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations View 151-17 (Right Rear, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 269 C4033 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 270 Fuel Pump Control Unit: Service and Repair FUEL PUMP DRIVER MODULE (FPDM) Removal and Installation 1. Remove the RH rear quarter trim panel. 2. Disconnect the fuel pump driver module (FPDM) electrical connector. 3. Remove the bolts and the FPDM. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 274 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 278 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Relay > Component Information > Locations > Page 283 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs Air Bag Control Module: Technical Service Bulletins Restraints - Control Module DTCs & Associated Fault PIDs TSB 07-12-3 06/25/07 RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS) - SERVICE TIPS FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred, Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar 2005-2007 Escape Hybrid, Escape 2007 E-Series LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator 2003-2007 Navigator 2006-2007 Mark LT MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan 2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 07-7-8 to update the vehicle application. ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most 2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS) terminology and navigation which does not translate well when using Integrated Diagnostic System (IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS). ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool being used. SERVICE TIPS DTCs And Associated Fault PIDs Description Many of the continuous memory and on-demand DTCs that can be present in the RCM provide general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional DTCs. Conventional DTCs identify a specific concern for a given component and point to a particular diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 289 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 290 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 291 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 292 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 293 DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s) or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the specific device and fault condition. Fault PIDs are available for both on-demand (active) and continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures 1-5) VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools have transitioned. Examples of how the WSM may direct you to view fault PIDs are: ^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 294 ^ View and Record DTC XXXXX Fault PIDs (2007 WSM) ^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs) In each instance the direction is the same (view fault PIDs to identify the specific component and fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology, will vary. FLAG the DTC - View the Fault PIDs For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is necessary to view the fault PIDs from DataLogger. Using IDS/PDS NOTE WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS, HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION. 1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous memory DTCs. 2. To view the fault PIDs associated with an on-demand DTC: a. Toolbox b. DataLogger c. Modules d. RCM 3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". ^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads "FAULT' indicating a front internal crash sensor fault. 4. To view the fault PIDs associated with a continuous memory DTC: a. Toolbox b. DataLogger c. Modules d. RCM 5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads "FAULT" indicating a front internal crash sensor fault. IDS/PDS Fault PID Naming Conventions The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example, the fault PIDs 2296_18_OD and 2296_18_CM break down as follows: ^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation. ^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC. ^ OD - Identifies the fault PID as an on-demand fault. ^ CM - Identifies the fault PID as a continuous memory (intermittent) fault. NOTE THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON VEHICLE EQUIPMENT. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 295 Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5) WARRANTY STATUS: Information Only Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 296 Air Bag Control Module: Locations View 151-12 (Center Console) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 297 View 151-13 (Left Front) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 298 Air Bag Control Module: Diagrams C310A Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 299 C310B (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 300 C310B (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 301 Air Bag Control Module: Description and Operation RESTRAINTS CONTROL MODULE (RCM) WARNING: - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, a new RCM must be installed whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. CAUTION: When installing a new RCM on vehicles built 7/31/06 or after, it is necessary to carry out programmable module installation (PMI). NOTE: When installing a new RCM, always make sure the correct RCM is being installed. If an incorrect RCM is installed, erroneous DTCs will result. The RCM carries out the following functions: - deploys the air bag(s) in the event of a deployable crash. - activates the safety belt buckle pretensioner and safety belt adaptive load limiting retractor to control tension on the safety belt. - monitors the SRS for faults. - requests the illumination of the air bag indicator if a fault is detected. - communicates through the DLC the on-demand or continuous DTCs. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the ON position, the RCM will request illumination of 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 6 seconds and then off. If a SRS fault exists, the air bag indicator will illuminate and remain illuminated for the rest of the key cycle. The RCM will also communicate the on-demand (current) and continuous (historical) DTCs through the DLC, to the scan tool. If the RCM requests illumination of the air bag indicator and the air bag indicator does not function, the instrument cluster module will automatically activate an audible chime. The chime is a series of 5 sets of 5 tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. 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 lost or damaged during impact. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 302 Air Bag Control Module: Service and Repair RESTRAINTS CONTROL MODULE (RCM) Special Tool(s) Special Tool(s) Removal WARNING: - Always wear safety glasses when repairing an air bag SRS vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - The RCM orientation is critical for correct air bag supplemental restraint system (SRS) operation. If a vehicle equipped with an SRS system has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the RCM must be installed new whether or not the air bags have deployed. In addition, make sure the area of Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 303 the RCM mounting is restored to its original condition. - Vehicle sensor orientation is critical for correct 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. Install a new sensor and correctly position the sensor or any other damaged SRS components whether or not the air bag is deployed. - The tightening torque of the air bag RCM retaining nuts is critical for correct system operation. - To reduce the risk of personal injury, do not use any memory saver devices. CAUTION: - Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. - When installing a new RCM on vehicles built 7/31/06 or after, it is necessary to carry out programmable module installation (PMI). See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning NOTE: - When installing a new RCM, always make sure the correct RCM is being installed. If an incorrect RCM is installed, erroneous DTCs will result. - 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 SRS fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. Vehicles built 7/31/06 or after 1. Carry out the steps necessary to prepare for programmable module installation (PMI). All vehicles 2. Depower the system. 3. Remove the floor console. 4. Disconnect the large restraints control module (RCM) electrical connector. 1 Pinch the thumb tab and pivot the large RCM electrical connector position assurance lever all the way back until it stops. 2 Pull out and disconnect the large RCM electrical connector. 5. Press to release the locking tab and disconnect the small RCM electrical connector. 6. Remove the 3 RCM nuts. 7. Remove the RCM. Installation All vehicles 1. Install the RCM. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 304 2. Install the 3 RCM nuts. - Tighten to 12 Nm (9 lb-ft). 3. Connect the small RCM electrical connector. 4. NOTE: The RCM has been removed for clarity. On the large RCM electrical connector, place the connector position assurance lever in the full release position. 5. CAUTION: Putting the large RCM electrical connector into the RCM on an angle can cause bad electrical connections and damage components. Position the large RCM electrical connector into the RCM. 6. Connect the large RCM connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 305 - CAUTION: Do not push the connector on to where the lever pivots and seats itself. Light pressure is needed to get the connector into position on the RCM before using the lever to fully seat the connector. With the large RCM electrical connector uniformly aligned to the RCM, lightly push in until a subtle audible click is heard and a slight resistance is felt. - Using the connector position assurance lever, pivot it toward the RCM, drawing the connector into the RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place. 7. Install the floor console. 8. Repower the system. Do not prove out the SRS at this time. Vehicles built 7/31/06 or after 9. Carry out the steps necessary to complete PMI. All vehicles 10. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch 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 6 seconds and then turn off. If an air bag SRS fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag indicator might not light 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 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 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous diagnostic trouble codes (DTCs) from the RCM and occupant classification sensor (OCS) module using a scan tool. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs Seat Belt Control Module: Technical Service Bulletins Restraints - Control Module DTCs & Associated Fault PIDs TSB 07-12-3 06/25/07 RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS) - SERVICE TIPS FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred, Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar 2005-2007 Escape Hybrid, Escape 2007 E-Series LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator 2003-2007 Navigator 2006-2007 Mark LT MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan 2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 07-7-8 to update the vehicle application. ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most 2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS) terminology and navigation which does not translate well when using Integrated Diagnostic System (IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS). ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool being used. SERVICE TIPS DTCs And Associated Fault PIDs Description Many of the continuous memory and on-demand DTCs that can be present in the RCM provide general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional DTCs. Conventional DTCs identify a specific concern for a given component and point to a particular diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 310 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 311 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 312 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 313 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 314 DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s) or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the specific device and fault condition. Fault PIDs are available for both on-demand (active) and continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures 1-5) VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools have transitioned. Examples of how the WSM may direct you to view fault PIDs are: ^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 315 ^ View and Record DTC XXXXX Fault PIDs (2007 WSM) ^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs) In each instance the direction is the same (view fault PIDs to identify the specific component and fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology, will vary. FLAG the DTC - View the Fault PIDs For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is necessary to view the fault PIDs from DataLogger. Using IDS/PDS NOTE WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS, HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION. 1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous memory DTCs. 2. To view the fault PIDs associated with an on-demand DTC: a. Toolbox b. DataLogger c. Modules d. RCM 3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". ^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads "FAULT' indicating a front internal crash sensor fault. 4. To view the fault PIDs associated with a continuous memory DTC: a. Toolbox b. DataLogger c. Modules d. RCM 5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads "FAULT" indicating a front internal crash sensor fault. IDS/PDS Fault PID Naming Conventions The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example, the fault PIDs 2296_18_OD and 2296_18_CM break down as follows: ^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation. ^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC. ^ OD - Identifies the fault PID as an on-demand fault. ^ CM - Identifies the fault PID as a continuous memory (intermittent) fault. NOTE THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON VEHICLE EQUIPMENT. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 316 Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5) WARRANTY STATUS: Information Only Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Description and Operation Seat Occupant Classification Module - Air Bag: Description and Operation OCS SYSTEM MODULE Based on programmed limits, the OCS module will inform the RCM, via a High Speed Controller Area Network (HS-CAN), of the necessary information. The RCM uses this information in determining if the passenger air bag module or passenger seat side air bag module is to be deployed in the event of a deployable collision. The OCS module monitors the OCS system for faults and communicates on-demand and continuous diagnostic trouble codes (DTCs) via the DLC with the use of a scan tool. The components that make up the OCS system, OCS system module, inboard OCS rail and outboard OCS rail are serviced separately. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Description and Operation > Page 320 Seat Occupant Classification Module - Air Bag: Service and Repair OCCUPANT CLASSIFICATION 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - Power seat shown, manual similar. - Seat is removed for clarity. 1. Depower the system. 2. From underneath the front of the seat, disconnect the OCS module electrical connector. 3. NOTE: Note the position of the locator tab on the OCS module for installation. Remove the 2 screws and the OCS module. To install, tighten to 2 Nm (18 lb-in). 4. To install, reverse the removal procedure. 5. Repower the SRS. Do not prove out the SRS at this time. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Description and Operation > Page 321 6. Carry out the appropriate procedure after installation of an OCS system component. - If installing the original OCS system component, carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. See: Restraint Systems/Air Bag Systems/Testing and Inspection/Component Tests and General Diagnostics/Occupant Classification Sensor (OCS) System Zero Seat Weight Test - If installing a new OCS system component, carry out the Occupant Classification Sensor (OCS) System Reset procedure and prove out the SRS. See: Restraint Systems/Air Bag Systems/Service and Repair Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Starter Relay Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Starter Relay > Page 327 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Run/Start Relay Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Run/Start Relay > Page 330 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM Control Module: Customer Interest A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM TSB 07-6-3 04/02/07 6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac MERCURY: 2006-2007 Mountaineer ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition vehicles may exhibit the following diagnostic trouble codes in the transmission control module (1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657, P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083, P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination at the mechatronic assembly. ACTION Follow the Service Procedure steps to correct the condition. NOTE IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM BARRIER STRIP. SERVICE PROCEDURE Remove the source of contamination from the transmission control unit (TCU)/solenoid connections and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent recurrence. 1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01. 2. Remove the six (6) long fasteners from the TCM unit. (Figure 1) 3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of the main control during this procedure. NOTE IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS SYSTEM. 4. Inspect the TCM at the following locations for metal chips or other metallic contamination. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 341 a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination. (Figure 2) b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure 3 and 4) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 342 c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure 5) 5. Prior to installation of the protective strip, remove all machining chips and or other metallic contamination from these areas with a clean, lint free cloth. 6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam barrier strip is installed). 7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first, "point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM, Section 307-01. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 343 8. Reinstall the mechatronic assembly following the WSM, Section 307-01. 9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01. 10. Set the transmission fluid level following the WSM, Section 307-01. 11. Clear all DTC(s) from the TCM. 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 070603A 2006-2007 2.6 Hrs. Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) 070603A 2007 Expedition 6R75 2.7 Hrs. Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) DEALER CODING CONDITION BASIC PART NO. CODE 14B167 49 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM Control Module: All Technical Service Bulletins A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM TSB 07-6-3 04/02/07 6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac MERCURY: 2006-2007 Mountaineer ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition vehicles may exhibit the following diagnostic trouble codes in the transmission control module (1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657, P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083, P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination at the mechatronic assembly. ACTION Follow the Service Procedure steps to correct the condition. NOTE IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM BARRIER STRIP. SERVICE PROCEDURE Remove the source of contamination from the transmission control unit (TCU)/solenoid connections and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent recurrence. 1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01. 2. Remove the six (6) long fasteners from the TCM unit. (Figure 1) 3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of the main control during this procedure. NOTE IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS SYSTEM. 4. Inspect the TCM at the following locations for metal chips or other metallic contamination. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 349 a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination. (Figure 2) b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure 3 and 4) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 350 c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure 5) 5. Prior to installation of the protective strip, remove all machining chips and or other metallic contamination from these areas with a clean, lint free cloth. 6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam barrier strip is installed). 7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first, "point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM, Section 307-01. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 351 8. Reinstall the mechatronic assembly following the WSM, Section 307-01. 9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01. 10. Set the transmission fluid level following the WSM, Section 307-01. 11. Clear all DTC(s) from the TCM. 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 070603A 2006-2007 2.6 Hrs. Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) 070603A 2007 Expedition 6R75 2.7 Hrs. Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) DEALER CODING CONDITION BASIC PART NO. CODE 14B167 49 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Rear Window Defrost Relay Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Rear Window Defrost Relay > Page 357 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Testing and Inspection > Rear Window Defrost Relay Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Testing and Inspection > Rear Window Defrost Relay > Page 360 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations View 151-25 (Liftgate) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 365 C4323 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 369 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations View 151-29 (Rear End) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left C4009 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 377 C4011 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 378 C4010 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 379 C4012 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 383 C2089 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Console Lamp Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door Console Lamp Switch: Service and Repair Door Ajar Switch - Front Door DOOR AJAR SWITCH - FRONT DOOR Removal and Installation 1. Remove the front door latch. 2. Disconnect the front door ajar switch electrical connector. 3. Release the locking tab and rotate the front door ajar switch counterclockwise and remove the switch from the front door latch. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Console Lamp Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 389 Console Lamp Switch: Service and Repair Door Ajar Switch - Rear Door DOOR AJAR SWITCH - REAR DOOR Removal and Installation 1. Remove the rear door latch. 2. Release the locking tab, rotate the rear door ajar switch counterclockwise and remove the switch from the rear door latch. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Console Lamp Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 390 Console Lamp Switch: Service and Repair Door Ajar Switch - Liftgate DOOR AJAR SWITCH - LIFTGATE Removal and Installation 1. Remove the liftgate latch. 2. Release the locking tab, rotate the liftgate ajar switch counterclockwise and remove the ajar switch form the liftgate latch. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Console Lamp Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 391 Console Lamp Switch: Service and Repair Door Ajar Switch - Liftgate Glass DOOR AJAR SWITCH - LIFTGATE GLASS Removal and Installation 1. Remove the liftgate window latch. 2. Rotate the liftgate window ajar switch counterclockwise and remove the ajar switch from the liftgate window latch. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 395 C2089 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side View 151-22 (Passenger Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side > Page 400 View 151-21 (Driver Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side C505 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side > Page 403 C605 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 404 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 405 Power Door Lock Switch: Service and Repair DOOR LOCK CONTROL SWITCH Removal and Installation NOTE: The LH side is shown, the RH side is similar. 1. Remove the interior door handle cover. 2. Remove the front door switch bezel. - Release the 4 retaining tabs. 3. Disconnect the door lock control switch and window control switch electrical connectors. 4. Remove the door lock control switch. - Release the 4 retaining tabs. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 406 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations View 151-21 (Driver Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 410 C527 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 411 Power Mirror Switch: Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 412 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 413 Power Mirror Switch: Service and Repair EXTERIOR MIRROR CONTROL SWITCH Removal and Installation 1. Remove the front door trim panel. 2. Remove the exterior mirror control switch from the front door trim panel. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left/Right View 151-16 (Left Rear, (2 0f 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left/Right > Page 418 View 151-19 (Driver Seat) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left/Right > Page 419 View 151-20 (Passenger Seat) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left Power Seat Switch: Diagrams Power Seat Switch, Left C352 C3016 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left > Page 422 C355 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left > Page 423 C4179 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left > Page 424 C4180 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left > Page 427 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left > Page 428 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Page 429 Power Seat Switch: Service and Repair MEMORY SET SWITCH Removal and Installation 1. Position the gear selector to NEUTRAL. 2. Remove the console trim ring. 3. Open the center console door, remove the 2 screws and pull up on the console finish panel to release the retainers. 4. Disconnect the power point electrical connector and remove the console finish panel. 5. Pull out to release the retainers and separate the instrument panel center lower RH and LH finish panels. 6. Pull out to release the retainers and separate the instrument panel center finish panel. 7. Disconnect the electrical connector, release the 4 tabs and remove the memory SET switch. 8. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations View 151-25 (Liftgate) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Page 433 C4039 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Belt Tower Position Sensor > Component Information > Description and Operation Seat Belt Tower Position Sensor: Description and Operation SEAT TRACK POSITION SENSOR The seat track position sensor is a Hall-effect sensor located on the driver seat track. The seat track position sensor informs the RCM of the driver seat position. Based on programmed limits, the seat track position sensor will inform the RCM of the driver seat position. The RCM uses this information in determining the deployment rate of the dual-stage driver air bag module. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 440 C2347 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch Seat Heater Switch: Service and Repair Heated Seat Switch HEATED SEAT SWITCH Removal and Installation 1. Position the gear selector to NEUTRAL. 2. Remove the console trim ring. 3. Open the center console door, remove the 2 screws and pull up on the console finish panel to release the retainers. 4. Disconnect the power point electrical connector and remove the console finish panel. 5. Pull out to release the retainers and separate the instrument panel center lower RH and LH finish panels. 6. Pull out to release the retainers and separate the instrument panel center finish panel. 7. Disconnect the electrical connector, release the 4 tabs and remove the heated seat/heated windshield switch pack. 8. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 443 Seat Heater Switch: Service and Repair Seat Control Switch SEAT CONTROL SWITCH Special Tool(s) Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 444 Front Seat Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 445 Front Seat Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 446 Driver Seat Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 447 Driver Seat Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 448 Passenger Seat Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 449 Passenger Seat Cushion (Part 2) Exploded View Removal and Installation WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an airbag module. This will reduce the risk of injury in the event of an accidental deployment. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - 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. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All seats 1. Remove the front seat and depower the supplemental restraint system (SRS). 2. Remove the cushion side shield. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 450 1. If equipped, remove the clip and manual recline handle. 2. If equipped, pull and remove the manual lumbar control knob. 3. Remove the scrivet. 4. Release the cushion side shield front clip. 5. From under the cushion side shield, release the 3 hook retainers. 6. Pull out on the cushion side shield at the back and release the pin-type retainer. 7. Separate the cushion trim cover elastic strap from the cushion side shield. 8. Remove the seat control switch knob and separate the seat control switch from the cushion side shield. - Remove the cushion side shield. 3. Disconnect and remove the seat control switch. 4. To install, reverse the removal procedure. 5. Install the front seat and repower the SRS. If a passenger seat has been serviced, do not prove out the SRS at this time. Passenger seat 6. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 451 Seat Heater Switch: Service and Repair Seat Control Switch - Third Row SEAT CONTROL SWITCH - THIRD ROW Removal and Installation 1. Pull out on the third row seat control switch bezel and separate from the LH quarter trim panel. 2. Disconnect the third row seat control switch(es), release the retainers and remove the third row seat control switch(es). 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 455 C2094 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Limit Switch > Component Information > Service and Repair Sunroof / Moonroof Limit Switch: Service and Repair ROOF OPENING PANEL CONTROL SWITCH Removal and Installation 1. Remove the overhead console. 2. Disconnect the overhead console electrical connectors. 3. Disengage the clips and remove the switch from the overhead console. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations View 151-26 (Roof) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 462 Sunroof / Moonroof Switch: Diagrams C912 C9001 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Service and Repair ABS Sensor Block: Service and Repair Stability Control Sensor Cluster Stability Control Sensor Cluster Removal and Installation NOTE: When installing a new stability control sensor cluster, the anti-lock brake system (ABS) module must be calibrated. Follow the scan tool directions for the calibration procedures. 1. Remove the pin-type retainer and the driver side floor console finish panel. 2. Remove the 2 bolts, 2 nuts and the LH instrument panel brace. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Service and Repair > Page 467 ^ To install, tighten to 9 Nm (80 inch lbs.). 3. Remove the 2 screws and LH heater duct. 4. Disconnect the stability control sensor cluster electrical connector. 5. Remove the stability control sensor cluster electrical harness retainers and position aside. 6. Remove the 2 stability control sensor cluster bracket nuts and the stability control sensor cluster. ^ To install, tighten to 7 Nm (62 inch lbs.). 7. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations View 151-2 (Engine Compartment - 4.0L, (2 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations > Page 471 C149 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations View 151-1 (Engine Compartment - 4.0L, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 475 C124 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Service and Repair Lateral Accelerometer: Service and Repair Stability Control Sensor Cluster Stability Control Sensor Cluster Removal and Installation NOTE: When installing a new stability control sensor cluster, the anti-lock brake system (ABS) module must be calibrated. Follow the scan tool directions for the calibration procedures. 1. Remove the pin-type retainer and the driver side floor console finish panel. 2. Remove the 2 bolts, 2 nuts and the LH instrument panel brace. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Service and Repair > Page 479 ^ To install, tighten to 9 Nm (80 inch lbs.). 3. Remove the 2 screws and LH heater duct. 4. Disconnect the stability control sensor cluster electrical connector. 5. Remove the stability control sensor cluster electrical harness retainers and position aside. 6. Remove the 2 stability control sensor cluster bracket nuts and the stability control sensor cluster. ^ To install, tighten to 7 Nm (62 inch lbs.). 7. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations View 151-13 (Left Front) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 483 C2015 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Service and Repair Steering Angle Sensor: Service and Repair Steering Wheel Rotation Sensor Steering Wheel Rotation Sensor Removal and Installation 1. Remove the 3 lower steering column cover bolts and the lower steering column cover. 2. Remove the upper steering column cover. 3. Disconnect the steering wheel rotation sensor electrical connector. 4. Remove the 2 bolts and the steering wheel rotation sensor. 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations View 151-11 (behind Dash Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 490 C280 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 491 Traction Control Switch: Service and Repair Stability/Traction Control Switch Removal and Installation 1. Remove the 2 floor console center finish panel screws and the floor console center finish panel. ^ To install, tighten to 9 Nm (80 inch lbs.). 2. Apply the parking brake. 3. Move the gear selector lever to the D1 position. 4. Position the instrument panel center finish panel away from the instrument panel. 5. Disconnect the stability traction control switch electrical connector and remove the stability traction control switch from the instrument panel Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 492 center finish panel. 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left/Right Front View 151-2 (Engine Compartment - 4.0L, (2 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left/Right Front > Page 497 View 151-15 (Left Rear, (1 0f 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left/Right Front > Page 498 View 151-17 (Right Rear, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front C150 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 501 C440 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 502 C160 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 503 C426 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Front Wheel Speed Sensor - Front Wheel Speed Sensor - Front Removal and Installation 1. Remove the front brake disc. 2. Disconnect the wheel speed sensor electrical connector. 3. Remove the wheel speed sensor harness bolt. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 506 4. Remove the wheel speed sensor harness pin-type retainers. 5. Remove the wheel speed sensor bolt. ^ To install, tighten to 17 Nm (13 ft. lbs.). 6. Remove the wheel speed sensor and the harness. 7. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 507 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Rear Wheel Speed Sensor - Rear Wheel Speed Sensor - Rear Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair 2. Disconnect the wheel speed sensor electrical connector. 3. Disconnect the wheel speed harness from the retainers. 4. Remove the wheel speed sensor bolt and the wheel speed sensor. ^ To install, tighten to 8 Nm (71 inch lbs.). 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations View 151-12 (Center Console) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 511 C3073 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 512 Yaw Rate Sensor: Service and Repair Stability Control Sensor Cluster Stability Control Sensor Cluster Removal and Installation NOTE: When installing a new stability control sensor cluster, the anti-lock brake system (ABS) module must be calibrated. Follow the scan tool directions for the calibration procedures. 1. Remove the pin-type retainer and the driver side floor console finish panel. 2. Remove the 2 bolts, 2 nuts and the LH instrument panel brace. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 513 ^ To install, tighten to 9 Nm (80 inch lbs.). 3. Remove the 2 screws and LH heater duct. 4. Disconnect the stability control sensor cluster electrical connector. 5. Remove the stability control sensor cluster electrical harness retainers and position aside. 6. Remove the 2 stability control sensor cluster bracket nuts and the stability control sensor cluster. ^ To install, tighten to 7 Nm (62 inch lbs.). 7. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Radiator Cooling Fan Speed Sensor > Component Information > Description and Operation Radiator Cooling Fan Speed Sensor: Description and Operation FAN SPEED SENSOR (FSS) Cooling Fan Clutch With (FSS) The FSS is a Hall-effect sensor that measures the cooling fan clutch speed by generating a waveform with a frequency proportional to the fan speed. If the cooling fan clutch is moving at a relatively low speed, the sensor produces a signal with a low frequency. As the cooling fan clutch speed increases, the sensor generates a signal with a higher frequency. The powertrain control module (PCM) uses the frequency signal generated by the FSS as a feedback for closed loop control of the cooling fan clutch. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 522 C1064 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 523 Coolant Temperature Sensor/Switch (For Computer): Description and Operation ENGINE COOLANT TEMPERATURE (ECT) SENSOR Typical Thread Type ECT Sensor The ECT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance changes 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 PCM uses the ECT input for fuel control and for cooling fan control. There are 3 types of ECT sensors, threaded, push-in, and twist-lock. The ECT sensor is located in an engine coolant passage. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 524 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR Removal and Installation 1. Drain the cooling system. 2. Disconnect the engine coolant temperature (ECT) sensor electrical connector. 3. Remove the clip and the ECT sensor. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Diagrams C107 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Diagrams > Page 528 Engine Temperature Sensor: Description and Operation CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical CHT Sensor The CHT sensor is a thermistor device in which resistance changes with the temperature. The electrical resistance of a thermistor decreases as temperature increases., and the resistance 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. The CHT sensor is installed in the 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 initiates a fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern 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. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch View 151-2 (Engine Compartment - 4.0L, (2 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch > Page 534 View 151-1 (Engine Compartment - 4.0L, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch C277 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch > Page 537 C278 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Brake Pedal Position (BPP) Switch Brake Switch (Cruise Control): Description and Operation Brake Pedal Position (BPP) Switch BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Brake Pedal Position (BPP) Switch > Page 540 Brake Switch (Cruise Control): Description and Operation Brake Pedal Switch (BPS) Brake Deactivator Switch BRAKE PEDAL SWITCH (BPS) BRAKE DEACTIVATOR SWITCH The BPS, also called the brake deactivator switch, is for vehicle speed control deactivation. A normally closed switch supplies battery positive voltage (B+) to the PCM when the brake pedal is not applied. When the brake pedal is applied, the normally closed switch opens and power is removed from the PCM. On some applications the normally closed BPS, along with the normally open BPP switch, are used for a brake rationality test within the PCM. The PCM misfire monitor profile learn function may be disabled if a brake switch concern occurs. If one or both brake pedal inputs to the PCM is not changing states when they were expected to, a diagnostic trouble code (DTC) is set by the PCM strategy. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Page 541 Brake Switch (Cruise Control): Service and Repair SPEED CONTROL DEACTIVATOR SWITCH Removal CAUTION: Do not remove or repair the brake pedal, brake booster or master cylinder without first removing the speed control deactivator switch. Do not install the speed control deactivator switch without the brake pedal arm secured to the brake booster push rod. Do not pull or push on the brake pedal when removing or installing the speed control deactivator switch, as misadjustment or damage to the switch may occur. 1. Disconnect the speed control deactivator switch electrical connector. 2. Rotate counterclockwise 45 degrees and remove the speed control deactivator switch. Installation NOTE: When installing the speed control deactivator switch it is automatically self-adjusting to the proper position. Do not pull up or push down on the pedal during installation. Initial installation of the speed control deactivator switch allows for one adjustment. If additional adjustments are necessary, install a new switch. 1. Install the speed control deactivator switch, and rotate clockwise 45 degrees. 2. Connect the speed control deactivator switch electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Description and Operation Clutch Switch: Description and Operation CLUTCH PEDAL POSITION (CPP) SWITCH Typical Clutch Pedal Position (CPP) Switch The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine load. The PCM uses the load information for mass air flow and fuel calculations. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair Cruise Control Switch: Service and Repair SPEED CONTROL SWITCH Removal and Installation NOTE: - It is not necessary to remove the driver air bag module during this procedure. - Be careful not to allow the speed control switch electrical connector to fall back into the steering wheel. 1. Remove the speed control switch by pulling the switch toward the rear of the vehicle. - Disconnect the electrical connector. 2. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations View 151-1 (Engine Compartment - 4.0L, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 552 C103 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Description and Operation Oil Temperature Sensor/Switch: Description and Operation ENGINE OIL TEMPERATURE (EOT) SENSOR Typical EOT Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance changes 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 EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system. The PCM can use the EOT sensor input to determine the following: - On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM begins reducing power by disabling engine cylinders. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Locations View 151-30 (Steering Wheel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Locations > Page 560 C2208 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations View 151-2 (Engine Compartment - 4.0L, (2 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 564 C132 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 565 Ambient Temperature Sensor / Switch HVAC: Service and Repair AMBIENT AIR TEMPERATURE SENSOR Removal and Installation Mountaineer 1. Remove the radiator grille. 2. Remove the pin-type retainers and position the air deflector forward. 3. Remove the 2 air deflector pin-type retainers and detach the air deflector from the 2 locator pins on the radiator support. All vehicles 4. Detach the ambient air temperature sensor electrical connector. 5. Remove the ambient air temperature sensor. 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations View 151-28 (Front HVAC) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 569 C271 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 570 Blower Motor Switch: Service and Repair BLOWER MOTOR SPEED CONTROL Removal and Installation 1. Remove the blower motor speed control screw. 2. Remove the blower motor speed control. 3. Disconnect the blower motor speed control electrical connector. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 574 C233 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 575 Cabin Temperature Sensor / Switch: Service and Repair IN-VEHICLE TEMPERATURE SENSOR Removal and Installation 1. Remove the instrument cluster finish panel. 2. Remove the in-vehicle temperature sensor. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation Evaporator Temperature Sensor / Switch: Description and Operation AIR CONDITIONING EVAPORATOR TEMPERATURE (ACET) SENSOR A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance The ACET sensor measures the evaporator air discharge temperature. The ACET sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The PCM sources a low current 5 volts on the ACET circuit. With SIG RTN also connected to the ACET sensor, the varying resistance changes the voltage drop across the sensor terminals. As A/C evaporator air temperature changes, the varying resistance of the ACET sensor changes the voltage the PCM detects. The ACET sensor is used to more accurately control A/C clutch cycling, improve defrost/demist performance, and reduce A/C clutch cycling. NOTE: These values can vary 15% due to sensor and VREF variations. Voltage values were calculated for VREF equals 5.0 volts. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations View 151-2 (Engine Compartment - 4.0L, (2 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 583 C1078 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations View 151-11 (behind Dash Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 587 C286 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Testing and Inspection > Page 592 Dimmer Switch: Service and Repair INSTRUMENT PANEL DIMMER SWITCH Removal and Installation 1. Remove the driver side register. 2. Remove the headlamp switch and bezel as an assembly. - Disconnect the electrical connectors. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Testing and Inspection > Page 593 3. Release the 2 tabs and remove the instrument panel dimmer switch. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front View 151-21 (Driver Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 598 View 151-22 (Passenger Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 599 View 151-24 (Left Rear Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 600 View 151-23 (Right Rear Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 601 Door Switch: Locations View 151-21 (Driver Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 602 View 151-22 (Passenger Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 603 View 151-24 (Left Rear Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 604 View 151-23 (Right Rear Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 605 View 151-25 (Liftgate) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 606 View 151-25 (Liftgate) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch C479 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 609 C478 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 610 C526 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 611 C602 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 612 Door Switch: Diagrams C479 C478 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 613 C526 C602 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 614 C715 C820 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 Fuel Gauge Sender: Customer Interest Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 TSB 06-17-10 09/04/06 MIL ON WITH DTC P0463 OR ERRATIC FUEL GAUGE OPERATION FORD: 2004-2007 Explorer MERCURY: 2004-2007 Mountaineer This article supersedes TSB 06-16-7 to update the Service Procedure. ISSUE Some 2004-2007 Explorer 4dr/Mountaineer vehicles may exhibit the malfunction indicator lamp (MIL) on with diagnostic trouble code (DTC) P0463 or an erratic fuel gauge concern. This could be from sulphur contamination in the fuel, causing an open or high resistance on the fuel sender card. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. For vehicles with customer symptom of erratic fuel gauge operation (with no MIL on), proceed to Step 1a. For vehicles with a customer symptom including the MIL on, proceed to Step 1b. If unable to verify the concern, do not continue with this TSB. a. Follow the appropriate pinpoint test (PPT) for "Fuel Gauge Inaccurate" in Workshop Manual (WSM), Section 413-01. If PPT test results lead to fuel pump module replacement, proceed to Step 2. If PPT test results isolate any problem other than fuel pump module replacement, repair as indicated and do not continue with this TSB. b. Install diagnostic scan tool to retrieve DTCs. If DTC P0463 is retrieved, proceed to Step 2. If DTC P0463 is not retrieved, this TSB does not apply, follow normal WSM diagnostics. 2. Remove fuel tank per WSM, Section 310-01. 3. Remove fuel pump assembly from fuel tank per WSM, Section 310-01. See Figure 1 (Chart) to determine if a kit (contains a fuel level sensor assembly, a wire harness and heat shrink tube) or fuel pump assembly is required for repair. For vehicles that can be serviced with a kit go to Step 4. For vehicles that require fuel pump assembly replacement, go to Step 12. 4. Remove the fuel level sensor assembly (sender card/float rod assembly) from the fuel pump assembly per WSM, Section 310-01. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 623 5. Detach electrical connector from fuel pump housing (Figure 2). 6. Remove wiring harness from the fuel pump assembly flange by depressing the retaining fingers on the harness connector at bottom of flange and pushing upward out of flange (Figure 3). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 624 7. Install new wiring harness by feeding wires through flange hole and inserting harness connector into flange until an audible click is heard. Check for proper retention. 8. Re-attach electrical connector harness to fuel pump housing. Prior to making the connection place one loop in the pump wires away from the convoluted feed tube (Figure 4). 9. Re-attach the signal wire (yellow) on the harness to the signal wire (yellow) on the replacement fuel level sensor assembly per WSM, Section 310-01 (Figure 5). 10. Wrap the ground wire one time around the signal wire and attach the ground wire terminal to the terminal on the fuel level sensor assembly. Check for proper retention. NOTE THE GROUND WIRE MUST BE WRAPPED AROUND THE SIGNAL WIRE, AS DESCRIBED IN STEP 10, TO PREVENT POTENTIAL INTERFERENCE WITH THE FLOAT ROD ARM. 11. Re-attach the fuel level sensor assembly to the fuel pump housing, making sure that both the signal wire and the ground wire are routed through the Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 625 gap between the fuel level sensor assembly and fuel pump bracket. Torque the fastener at the bottom of the fuel level sensor assembly to 1 N.m (9 lb-in). 12. Re-install fuel pump assembly into fuel tank per WSM, Section 310-01. NOTE TAKE CARE NOT TO DAMAGE/BEND FLOAT ROD OR SENDER CARD DURING INSTALLATION OF FUEL PUMP ASSEMBLY. 13. Re-install fuel tank per WSM, Section 310-01. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 061710A 2004-2007 2.9 Hrs. Explorer/Mountaineer: Diagnose And Replace The Fuel Gauge Tank Unit (Do Not Use With 9275D, 9275A, 9002A) DEALER CODING CONDITION BASIC PART NO. CODE 9A299 28 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 Fuel Gauge Sender: All Technical Service Bulletins Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 TSB 06-17-10 09/04/06 MIL ON WITH DTC P0463 OR ERRATIC FUEL GAUGE OPERATION FORD: 2004-2007 Explorer MERCURY: 2004-2007 Mountaineer This article supersedes TSB 06-16-7 to update the Service Procedure. ISSUE Some 2004-2007 Explorer 4dr/Mountaineer vehicles may exhibit the malfunction indicator lamp (MIL) on with diagnostic trouble code (DTC) P0463 or an erratic fuel gauge concern. This could be from sulphur contamination in the fuel, causing an open or high resistance on the fuel sender card. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. For vehicles with customer symptom of erratic fuel gauge operation (with no MIL on), proceed to Step 1a. For vehicles with a customer symptom including the MIL on, proceed to Step 1b. If unable to verify the concern, do not continue with this TSB. a. Follow the appropriate pinpoint test (PPT) for "Fuel Gauge Inaccurate" in Workshop Manual (WSM), Section 413-01. If PPT test results lead to fuel pump module replacement, proceed to Step 2. If PPT test results isolate any problem other than fuel pump module replacement, repair as indicated and do not continue with this TSB. b. Install diagnostic scan tool to retrieve DTCs. If DTC P0463 is retrieved, proceed to Step 2. If DTC P0463 is not retrieved, this TSB does not apply, follow normal WSM diagnostics. 2. Remove fuel tank per WSM, Section 310-01. 3. Remove fuel pump assembly from fuel tank per WSM, Section 310-01. See Figure 1 (Chart) to determine if a kit (contains a fuel level sensor assembly, a wire harness and heat shrink tube) or fuel pump assembly is required for repair. For vehicles that can be serviced with a kit go to Step 4. For vehicles that require fuel pump assembly replacement, go to Step 12. 4. Remove the fuel level sensor assembly (sender card/float rod assembly) from the fuel pump assembly per WSM, Section 310-01. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 631 5. Detach electrical connector from fuel pump housing (Figure 2). 6. Remove wiring harness from the fuel pump assembly flange by depressing the retaining fingers on the harness connector at bottom of flange and pushing upward out of flange (Figure 3). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 632 7. Install new wiring harness by feeding wires through flange hole and inserting harness connector into flange until an audible click is heard. Check for proper retention. 8. Re-attach electrical connector harness to fuel pump housing. Prior to making the connection place one loop in the pump wires away from the convoluted feed tube (Figure 4). 9. Re-attach the signal wire (yellow) on the harness to the signal wire (yellow) on the replacement fuel level sensor assembly per WSM, Section 310-01 (Figure 5). 10. Wrap the ground wire one time around the signal wire and attach the ground wire terminal to the terminal on the fuel level sensor assembly. Check for proper retention. NOTE THE GROUND WIRE MUST BE WRAPPED AROUND THE SIGNAL WIRE, AS DESCRIBED IN STEP 10, TO PREVENT POTENTIAL INTERFERENCE WITH THE FLOAT ROD ARM. 11. Re-attach the fuel level sensor assembly to the fuel pump housing, making sure that both the signal wire and the ground wire are routed through the Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 633 gap between the fuel level sensor assembly and fuel pump bracket. Torque the fastener at the bottom of the fuel level sensor assembly to 1 N.m (9 lb-in). 12. Re-install fuel pump assembly into fuel tank per WSM, Section 310-01. NOTE TAKE CARE NOT TO DAMAGE/BEND FLOAT ROD OR SENDER CARD DURING INSTALLATION OF FUEL PUMP ASSEMBLY. 13. Re-install fuel tank per WSM, Section 310-01. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 061710A 2004-2007 2.9 Hrs. Explorer/Mountaineer: Diagnose And Replace The Fuel Gauge Tank Unit (Do Not Use With 9275D, 9275A, 9002A) DEALER CODING CONDITION BASIC PART NO. CODE 9A299 28 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 634 Fuel Gauge Sender: Description and Operation FUEL PUMP (FP) MODULE Typical Electronic Returnless Fuel Pump (FP) Module Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 635 Typical Mechanical Returnless Fuel Pump (FP) Module The FP module 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. FUEL PUMP (FP) MODULE AND RESERVOIR The FP module is mounted inside the fuel tank in a reservoir. The pump has a discharge check valve that maintains the system pressure after the key has been turned off to minimize starting concerns. The reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low tank fill levels. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 636 Fuel Gauge Sender: Service and Repair FUEL LEVEL SENSOR Explorer Sport Trac (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 637 Explorer Sport Trac (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 638 Explorer/Mountaineer (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 639 Explorer/Mountaineer (Part 2) All Vehicles (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 640 All Vehicles (Part 2) Removal 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. 1. Remove the fuel pump. 2. NOTE: Note the routing of the sending unit wire for installation. Remove the heat shrink tube covering the electrical connector. 3. Disconnect the electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 641 4. Remove the screw and lift up to remove the fuel gauge sending unit. Installation 1. Route the fuel gauge sending unit wire through the center of the fuel pump module. 2. NOTE: - Both fuel gauge sending wires must be routed behind the metal sending unit plate. - The grounding eyelet must be on the front side of the sending unit. Hook the fuel gauge sending unit on the fuel pump module and install the screw through the grounding eyelet and tighten the screw. 3. Slide the heat shrink tube onto the wire harness and connect the electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 642 4. WARNING: Do not use an open flame to shrink the heat shrink tube, use a heat gun only. Failure to follow these instructions may result in personal injury. Using a heat gun, shrink the heat shrink tube. 5. Install the fuel pump. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations View 151-13 (Left Front) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 646 C2015 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations View 151-11 (behind Dash Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 651 C286 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 652 Ambient Light Sensor: Service and Repair LIGHT SENSOR Removal and Installation 1. Position the top portion of the lower center instrument panel finish panel rearward. 2. Remove the upper center instrument panel finish panel. - Disconnect the electrical connector. 3. Remove the 2 screws and the light sensor. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 656 C167 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 657 Backup Lamp Switch: Testing and Inspection Digital Transmission Range (TR) Sensor Diagnosis Chart Digital Transmission Range (TR) Sensor Diagnosis Chart Wiggle Test Information for Open/Shorts ^ TR4, TR3A, TR2 and TR1 are all closed in PARK. PARK is a good position to check for intermittent open circuits (with scan tool monitoring TRD). ^ TR4, TR3A, TR2 and TR1 are all open in OVERDRIVE, so OVERDRIVE is a good position to check for shorts to ground. To determine the shorted components while observing TRD, unplug the TR and determine if the short goes away. If the short is still present unplug the transmission harness and determine if the short goes away. If the short is still present, then the short is in the PCM or vehicle harness. Remove the suspect circuit(s) wire terminal from the PCM connector. If the short is still present, then the PCM has an internal failure, otherwise the failure is in the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations View 151-1 (Engine Compartment - 4.0L, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 661 C278 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 662 Brake Light Switch: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 663 Brake Light Switch: Service and Repair STOPLAMP SWITCH Removal and Installation CAUTION: Do not remove or repair the brake pedal, brake booster or master cylinder without first removing the stoplamp switch. Do not install the stoplamp switch without the brake pedal arm secured to the brake booster push rod. Do not pull or push on the brake pedal when removing or installing the stoplamp switch, as misadjustment or damage to the switch may occur. 1. Disconnect the stoplamp switch electrical connector. 2. Rotate the stoplamp switch 45 degrees clockwise and remove the stoplamp switch. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Console Lamp Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door Console Lamp Switch: Service and Repair Door Ajar Switch - Front Door DOOR AJAR SWITCH - FRONT DOOR Removal and Installation 1. Remove the front door latch. 2. Disconnect the front door ajar switch electrical connector. 3. Release the locking tab and rotate the front door ajar switch counterclockwise and remove the switch from the front door latch. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Console Lamp Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 668 Console Lamp Switch: Service and Repair Door Ajar Switch - Rear Door DOOR AJAR SWITCH - REAR DOOR Removal and Installation 1. Remove the rear door latch. 2. Release the locking tab, rotate the rear door ajar switch counterclockwise and remove the switch from the rear door latch. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Console Lamp Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 669 Console Lamp Switch: Service and Repair Door Ajar Switch - Liftgate DOOR AJAR SWITCH - LIFTGATE Removal and Installation 1. Remove the liftgate latch. 2. Release the locking tab, rotate the liftgate ajar switch counterclockwise and remove the ajar switch form the liftgate latch. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Console Lamp Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 670 Console Lamp Switch: Service and Repair Door Ajar Switch - Liftgate Glass DOOR AJAR SWITCH - LIFTGATE GLASS Removal and Installation 1. Remove the liftgate window latch. 2. Rotate the liftgate window ajar switch counterclockwise and remove the ajar switch from the liftgate window latch. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front View 151-21 (Driver Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 675 View 151-22 (Passenger Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 676 View 151-24 (Left Rear Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 677 View 151-23 (Right Rear Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 678 Door Switch: Locations View 151-21 (Driver Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 679 View 151-22 (Passenger Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 680 View 151-24 (Left Rear Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 681 View 151-23 (Right Rear Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 682 View 151-25 (Liftgate) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 683 View 151-25 (Liftgate) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch C479 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 686 C478 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 687 C526 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 688 C602 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 689 Door Switch: Diagrams C479 C478 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 690 C526 C602 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 691 C715 C820 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Illumination Dimmer Switch View 151-11 (behind Dash Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Illumination Dimmer Switch > Page 696 View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch C202 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch > Page 699 C2298 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 700 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 701 Headlamp Dimmer Switch: Service and Repair Steering Column Multifunction Switch Steering Column Multifunction Switch Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column can result. 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the 2 screws and the steering column opening cover. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 702 3. Remove the 3 screws and the upper and lower steering column shroud. 4. Disconnect the multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the multi-function switch. 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations View 151-11 (behind Dash Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 706 C205 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 707 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 708 Headlamp Switch: Service and Repair HEADLAMP SWITCH Removal and Installation 1. Remove the driver side register. 2. Remove the headlamp switch and bezel as an assembly. - Disconnect the electrical connectors. 3. Remove the 3 screws and the headlamp switch. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations View 151-30 (Steering Wheel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 715 C202 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 716 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 717 Turn Signal Switch: Service and Repair Steering Column Multifunction Switch Steering Column Multifunction Switch Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column can result. 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the 2 screws and the steering column opening cover. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 718 3. Remove the 3 screws and the upper and lower steering column shroud. 4. Disconnect the multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the multi-function switch. 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations View 151-11 (behind Dash Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 724 C2040 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 725 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The APP sensor is an input to the powertrain control module (PCM) and is used to determine the torque demand. There are 3 pedal position signals in the sensor. Signal 1, APPS1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, APPS2 and APPS3, both have a positive slope (increasing angle, increasing voltage). During normal operation APPS1 is used as the indication of pedal position by the strategy. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. There are 2 reference voltage circuits and 2 signal return circuits for the sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 729 C128 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 730 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW (MAF) SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT Sensor Wire Where Applicable) Terminals Typical Mass Air Flow (MAF) Sensor Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 731 Typical Drop-in Mass Air Flow (MAF) Sensor The 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 the ambient temperature as measured by a constant cold wire. The current required to maintain the temperature of the hot wire is proportional to the mass air 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. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Most MAF sensors have integrated bypass technology with an integrated intake air temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 732 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Disconnect the mass air flow (MAF) sensor electrical connector. 2. Remove the bolts and the MAF. - To install, tighten to 2 Nm (18 lb-in). 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor C180 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 738 C1366 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 739 C1367 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 740 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR Typical Synchronizer Hall-Effect CMP Sensor Typical Variable Reluctance CMP Sensor The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to select the correct ignition coil to fire. Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor and the 2-pin connector variable reluctance type sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 741 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation 1. Disconnect the camshaft position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. - To install, tighten to 6 Nm (53 lb-in). 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Description and Operation Clutch Switch: Description and Operation CLUTCH PEDAL POSITION (CPP) SWITCH Typical Clutch Pedal Position (CPP) Switch The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine load. The PCM uses the load information for mass air flow and fuel calculations. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Locations > Page 748 C1064 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Locations > Page 749 Coolant Temperature Sensor/Switch (For Computer): Description and Operation ENGINE COOLANT TEMPERATURE (ECT) SENSOR Typical Thread Type ECT Sensor The ECT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance changes 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 PCM uses the ECT input for fuel control and for cooling fan control. There are 3 types of ECT sensors, threaded, push-in, and twist-lock. The ECT sensor is located in an engine coolant passage. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Locations > Page 750 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR Removal and Installation 1. Drain the cooling system. 2. Disconnect the engine coolant temperature (ECT) sensor electrical connector. 3. Remove the clip and the ECT sensor. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 754 Crankshaft Position Sensor: Diagrams C101 C1120 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 755 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Typical Crankshaft Position (CKP) Sensor The 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 PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L 10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor 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 a fixed reference for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid deceleration between teeth. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 756 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). 4. NOTE: Be sure the sensor wiring is routed away from the battery cable. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Diagrams C107 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Diagrams > Page 760 Engine Temperature Sensor: Description and Operation CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical CHT Sensor The CHT sensor is a thermistor device in which resistance changes with the temperature. The electrical resistance of a thermistor decreases as temperature increases., and the resistance 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. The CHT sensor is installed in the 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 initiates a fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern 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. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations View 151-14 (Right Front) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 764 Fuel Level Sensor: Diagrams C434A C434B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 765 Fuel Level Sensor: Description and Operation FUEL LEVEL INPUT (FLI) The FLI is a communications network message. Most vehicle applications use a potentiometer type FLI sensor connected to a float in the FP module to determine fuel level. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 766 Fuel Level Sensor: Service and Repair FUEL LEVEL SENSOR Explorer Sport Trac (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 767 Explorer Sport Trac (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 768 Explorer/Mountaineer (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 769 Explorer/Mountaineer (Part 2) All Vehicles (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 770 All Vehicles (Part 2) Removal 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. 1. Remove the fuel pump. 2. NOTE: Note the routing of the sending unit wire for installation. Remove the heat shrink tube covering the electrical connector. 3. Disconnect the electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 771 4. Remove the screw and lift up to remove the fuel gauge sending unit. Installation 1. Route the fuel gauge sending unit wire through the center of the fuel pump module. 2. NOTE: - Both fuel gauge sending wires must be routed behind the metal sending unit plate. - The grounding eyelet must be on the front side of the sending unit. Hook the fuel gauge sending unit on the fuel pump module and install the screw through the grounding eyelet and tighten the screw. 3. Slide the heat shrink tube onto the wire harness and connect the electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 772 4. WARNING: Do not use an open flame to shrink the heat shrink tube, use a heat gun only. Failure to follow these instructions may result in personal injury. Using a heat gun, shrink the heat shrink tube. 5. Install the fuel pump. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE (FTP) SENSOR Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The FTP sensor or in-line FTP sensor is used to measure the fuel tank pressure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Page 776 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR Removal and Installation WARNING: - The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not present in large quantities, it still presents a danger or 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 cause 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. 1. Remove the evaporative emission (EVAP) canister. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Page 777 2. Remove the fuel tank shield from the fuel tank. 3. Disconnect the fuel tank pressure sensor electrical connector. 4. Disconnect the 3 fuel tank pressure sensor and tube assembly quick connect couplings from the fuel pump module and the vapor vent valves. 5. Remove the fuel tank pressure sensor and tube assembly. 6. To install, reverse the removal procedure. 7. Leak test the evaporative emission system. See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Evaporative Emission System Leak Test 8. Carry out the evaporative emission repair verification drive cycle. See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Evaporative Emission Repair Verification Drive Cycle Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 781 C128 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 782 Intake Air Temperature Sensor: Description and Operation INTAKE AIR TEMPERATURE (IAT) SENSOR Typical Stand-Alone/Non-Integrated Intake Air Temperature (IAT) Sensors Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into A Drop-in Or Flange-type MAF Sensor The IAT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance 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 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 air flow. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 783 The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Currently there are 2 design types of IAT sensors used, a stand-alone/non-integrated type and a integrated type. Both types function the same, however the integrated type is incorporated into the mass air flow (MAF) sensor instead of being a stand alone sensor. Supercharged vehicles use 2 IAT sensors. Both sensors are thermistor type devices and operate as described. One is located before the supercharger at the air cleaner for standard OBD/cold weather input, while a second sensor (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 spark and to help determine charge air cooler (CAC) efficiency. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 787 C108 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 788 Knock Sensor: Description and Operation KNOCK SENSOR (KS) Two Types Of Knock Sensor (KS) The KS 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 789 Knock Sensor: Service and Repair KNOCK SENSOR (KS) Removal and Installation 1. Remove the intake manifold. 2. Disconnect the knock sensor (KS) electrical connector. 3. Remove the bolt and the KS. - To install, tighten to 20 Nm (15 lb-ft). 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation Manifold Pressure/Vacuum Sensor: Description and Operation MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR Typical Manifold Absolute Pressure (MAP) Sensor The MAP sensor measures intake manifold absolute pressure. The PCM uses information from the MAP sensor to measure how much exhaust gas is introduced into the intake manifold. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Diagrams C104 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Diagrams > Page 796 Oil Temperature Sensor For ECM: Description and Operation ENGINE OIL TEMPERATURE (EOT) SENSOR Typical EOT Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance changes 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 EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system. The PCM can use the EOT sensor input to determine the following: - On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM begins reducing power by disabling engine cylinders. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Diagrams > Page 797 Oil Temperature Sensor For ECM: Service and Repair OIL TEMPERATURE SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine oil. - Install the drain plug and tighten to 26 Nm (19 lb-ft). 3. Disconnect the oil temperature sensor electrical connector. 4. Remove the oil temperature sensor. - To install, tighten to 15 Nm (11 lb-ft). 5. To install, reverse the removal procedure. - Inspect the O-ring seal and install a new O-ring seal if necessary. - Fill the engine with clean engine oil. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 802 View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 803 View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 804 View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 C141 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 807 C142 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 808 C171 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 809 C172 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 810 Oxygen Sensor: Description and Operation HEATED OXYGEN SENSOR (HO2S) Heated Oxygen Sensor (HO2S) The HO2S 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 voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a 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 a temperature of 800°C (1,472°F). At approximately 300°C (572°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater. The PCM turns the heater on by providing the ground when the correct conditions occur. The heater allows the engine to enter closed loop operation sooner. The use of this heater requires the HO2S heater control to be duty cycled, to prevent damage to the heater. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) HEATED OXYGEN SENSOR (HO2S) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 813 Exploded View Special Tool(s) Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If the RH heated oxygen sensor (HO2S) is being serviced, remove the bolts and position the heat shield aside. - To install, tighten to 20 Nm (15 lb-ft). 3. Disconnect the HO2S electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 814 4. NOTE: If necessary, lubricate the HO2S with penetrating and lock lubricant to ease removal. Using the special tool, remove the HO2S. To install, tighten to 41 Nm (30 lb-ft). 5. To install, reverse the removal procedure. - Apply a light coat of nickel anti-seize lubricant to the threads of the HO2S. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 815 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor CATALYST MONITOR SENSOR Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 816 Exploded View Special Tool(s) Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the catalyst monitor sensor electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 817 3. NOTE: If necessary, lubricate the catalyst monitor sensor with penetrating and lock lubricant to ease removal. Using the special tool, remove the catalyst monitor sensor. To install, tighten to 41 Nm (30 lb-ft). 4. To install, reverse the removal procedure. - Apply a light coat of anti-seize lubricant to the threads of the catalyst monitor sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations View 151-2 (Engine Compartment - 4.0L, (2 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 821 C121 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch POWER STEERING PRESSURE (PSP) SWITCH Typical Power Steering Pressure (PSP) Switch The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch > Page 824 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor POWER STEERING PRESSURE (PSP) SENSOR Typical Power Steering Pressure (PSP) Sensor The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM changes as the hydraulic pressure changes. The PCM uses the input signal from the PSP sensor to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP sensor signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example, during parking maneuvers. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Description and Operation Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor The differential pressure feedback EGR sensor 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 EGR sensor receives this signal through 2 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 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. DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR TUBE MOUNTED Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Description and Operation > Page 828 The tube mounted differential pressure feedback EGR sensor is identical in operation as the large plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Description and Operation > Page 829 Pressure Feedback Exhaust Sensor: Service and Repair EXHAUST GAS RECIRCULATION (EGR) SYSTEM MODULE Exploded View Removal and Installation 1. Disconnect the exhaust gas recirculation (EGR) system module electrical and vacuum connectors. 2. Disconnect the EGR system module-to-exhaust manifold tube upper fitting. - To install, tighten to 40 Nm (30 lb-ft). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Description and Operation > Page 830 3. NOTE: When installing the new EGR module gasket, install with the side with the raised circle facing the intake manifold. Remove the bolts, the EGR system module and the gasket. Discard the gasket. To install, tighten to 25 Nm (18 lb-ft). 4. NOTE: The EGR system module sealing surfaces are soft metals. Carefully clean the EGR system module sealing surfaces. 5. To install, reverse the removal procedure. - Install a new EGR system module gasket. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 834 C189 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Electronic Throttle Body (ETB) Position Sensor Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR The ETB position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB position signals are required for increased monitoring. The first ETB position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). During normal operation the negative slope ETB position sensor signal (TP1) is used by the control strategy as the indication of throttle position. The 2 ETB position sensor signals make sure the PCM receives a correct input even if 1 signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Electronic Throttle Body (ETB) Position Sensor > Page 837 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor THROTTLE POSITION (TP) SENSOR Typical TP Sensor The TP sensor 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 3-blade electrical connector that may be gold plated. The gold plating increases the corrosion resistance on the terminals and increases the connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM from the TP. The operating 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) - throttle angle rate Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 838 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Removal Vehicles equipped with a 4.6L (3V) engine 1. Remove the air cleaner outlet pipe. 2. Remove the bolts and position the heated positive crankcase ventilation (PCV) fitting and hoses aside. - Remove and discard the O-ring seal. All vehicles 3. Disconnect the throttle position (TP) sensor electrical connector. 4. CAUTION: Failure to remove the TP sensor screws in the following manner will result in damage to the screws. First loosen the screws 1-2 full turns using a hand tool and then use a suitable high-speed driver to complete the removal. Remove and discard the 2 screws and the TP sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 839 Installation All vehicles 1. CAUTION: - Do not reuse the TP sensor and screws. A new TP sensor and screws must be installed. - Do not use a high-speed driver to install the new screws or damage to the TP sensor can occur. NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor is aligned with the radial locator hole on the throttle body. Position the new TP sensor and install the 2 new screws. Tighten to 3 Nm (27 lb-in). 2. Connect the TP sensor electrical connector. Vehicles equipped with a 4.6L (3V) engine 3. Install a new O-ring seal, position the heated PCV fitting and install the bolts. 4. Install the air cleaner outlet pipe. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 845 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 846 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 847 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 848 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 849 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 850 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 851 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 852 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 853 Transmission Position Switch/Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 854 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 855 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 856 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 857 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 858 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 859 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 860 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 861 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 862 C167 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 863 Transmission Position Switch/Sensor: Testing and Inspection Digital Transmission Range (TR) Sensor Diagnosis Chart Digital Transmission Range (TR) Sensor Diagnosis Chart Wiggle Test Information for Open/Shorts ^ TR4, TR3A, TR2 and TR1 are all closed in PARK. PARK is a good position to check for intermittent open circuits (with scan tool monitoring TRD). ^ TR4, TR3A, TR2 and TR1 are all open in OVERDRIVE, so OVERDRIVE is a good position to check for shorts to ground. To determine the shorted components while observing TRD, unplug the TR and determine if the short goes away. If the short is still present unplug the transmission harness and determine if the short goes away. If the short is still present, then the short is in the PCM or vehicle harness. Remove the suspect circuit(s) wire terminal from the PCM connector. If the short is still present, then the PCM has an internal failure, otherwise the failure is in the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 864 Transmission Position Switch/Sensor: Adjustments Transmission Range (TR) Sensor Adjustment Special Tool(s) Adjust 1. With the vehicle in NEUTRAL, position it on a hoist For additional information, refer to Maintenance/Service and Repair. 2. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the connector. 4. Disconnect the digital transmission range (TR) sensor electrical connector. 5. Remove the range selector lever cable end from the manual control lever. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 865 6. Remove the outer manual control lever. 7. Loosen but do not remove the digital TR sensor screws. 8. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. ^ Tighten to 8 Nm (71 inch lbs.) 9. Install the outer manual lever. ^ Tighten to 48 Nm (35 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 866 10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable end onto the manual control lever. 11. Reconnect the digital TR sensor electrical connector. 12. Move the rubber boot back over the connector. 13. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 867 14. Verify that the selector lever cable is adjusted correctly. 15. Verify that the vehicle will start in PARK and NEUTRAL and that the reverse lamps illuminate in REVERSE. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 868 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the connector. 4. Disconnect the digital transmission range (TR) sensor electrical connector. 5. Remove the selector lever cable from the manual control lever. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 869 6. Remove the outer manual control lever. 7. Remove the digital TR sensor. Installation 1. CAUTION: The digital transmission range sensor must fit flush against the boss on the case to prevent damage to the sensor. Install the digital TR sensor and 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 be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 870 ^ Tighten to 8 Nm (71 inch lbs.) 3. Install the outer manual lever. ^ Tighten to 48 Nm (35 ft. lbs.) 4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable to the manual control lever. 5. Connect the digital TR sensor electrical connector. 6. Move the rubber boot back over the connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 871 7. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. 8. Verify that the selector lever cable is adjusted correctly. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Output Shaft Speed (OSS) Sensor Vehicle Speed Sensor: Description and Operation Output Shaft Speed (OSS) Sensor OUTPUT SHAFT SPEED (OSS) SENSOR The OSS sensor provides the 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 that is generated. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Output Shaft Speed (OSS) Sensor > Page 876 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) VEHICLE SPEED SENSOR (VSS) Typical Vehicle Speed Sensor (VSS) The VSS 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor The differential pressure feedback EGR sensor 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 EGR sensor receives this signal through 2 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 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. DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR TUBE MOUNTED Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 881 The tube mounted differential pressure feedback EGR sensor is identical in operation as the large plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 882 Pressure Feedback Exhaust Sensor: Service and Repair EXHAUST GAS RECIRCULATION (EGR) SYSTEM MODULE Exploded View Removal and Installation 1. Disconnect the exhaust gas recirculation (EGR) system module electrical and vacuum connectors. 2. Disconnect the EGR system module-to-exhaust manifold tube upper fitting. - To install, tighten to 40 Nm (30 lb-ft). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 883 3. NOTE: When installing the new EGR module gasket, install with the side with the raised circle facing the intake manifold. Remove the bolts, the EGR system module and the gasket. Discard the gasket. To install, tighten to 25 Nm (18 lb-ft). 4. NOTE: The EGR system module sealing surfaces are soft metals. Carefully clean the EGR system module sealing surfaces. 5. To install, reverse the removal procedure. - Install a new EGR system module gasket. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations View 151-11 (behind Dash Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 888 C2040 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 889 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The APP sensor is an input to the powertrain control module (PCM) and is used to determine the torque demand. There are 3 pedal position signals in the sensor. Signal 1, APPS1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, APPS2 and APPS3, both have a positive slope (increasing angle, increasing voltage). During normal operation APPS1 is used as the indication of pedal position by the strategy. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. There are 2 reference voltage circuits and 2 signal return circuits for the sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 893 C128 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 894 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW (MAF) SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT Sensor Wire Where Applicable) Terminals Typical Mass Air Flow (MAF) Sensor Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 895 Typical Drop-in Mass Air Flow (MAF) Sensor The 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 the ambient temperature as measured by a constant cold wire. The current required to maintain the temperature of the hot wire is proportional to the mass air 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. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Most MAF sensors have integrated bypass technology with an integrated intake air temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 896 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Disconnect the mass air flow (MAF) sensor electrical connector. 2. Remove the bolts and the MAF. - To install, tighten to 2 Nm (18 lb-in). 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Locations > Fuel Tank Pressure Transducer Sensor View 151-14 (Right Front) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Locations > Fuel Tank Pressure Transducer Sensor > Page 901 View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Fuel Rail Pressure/Temperature Sensor C173 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Fuel Rail Pressure/Temperature Sensor > Page 904 C435 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Rail Pressure (FRP) Sensor Fuel Pressure Sensor/Switch: Description and Operation Fuel Rail Pressure (FRP) Sensor FUEL RAIL PRESSURE (FRP) SENSOR Fuel Rail Pressure (FRP) Sensor The FRP sensor is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and the resistance decreases as the 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. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Rail Pressure (FRP) Sensor > Page 907 Fuel Pressure Sensor/Switch: Description and Operation Fuel Rail Pressure Temperature (FRPT) Sensor FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR Typical Fuel Rail Pressure Temperature (FRPT) Sensor The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to determine the pressure difference between the fuel rail and the intake manifold. The relationship between fuel pressure and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. The temperature sensing portion of the FRPT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of the thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Both the pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves 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 (V6-4.0L VIN K (2007)) 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 > Page 908 Fuel Pressure Sensor/Switch: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE SENSOR Removal and Installation 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. Release the fuel system pressure. 2. Remove the intake manifold. 3. Disconnect the fuel rail pressure and temperature sensor vacuum and electrical connectors. 4. Remove the bolts and the fuel rail pressure and temperature sensor. - To install, tighten to 6 Nm (53 lb-in). 5. Remove and discard the O-ring seal. 6. CAUTION: Use an O-ring seal made of special fuel resistant material. Use of an ordinary O-ring seal can cause the fuel system to leak. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Page 909 Do not reuse the O-ring seal. To install, reverse the removal procedure. Lubricate the new O-ring seal with clean engine oil. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 913 C173 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 914 Fuel Temperature Sensor: Description and Operation FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR Typical Fuel Rail Pressure Temperature (FRPT) Sensor The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to determine the pressure difference between the fuel rail and the intake manifold. The relationship between fuel pressure and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. The temperature sensing portion of the FRPT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of the thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Both the pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 915 Fuel Temperature Sensor: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE SENSOR Removal and Installation 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. Release the fuel system pressure. 2. Remove the intake manifold. 3. Disconnect the fuel rail pressure and temperature sensor vacuum and electrical connectors. 4. Remove the bolts and the fuel rail pressure and temperature sensor. - To install, tighten to 6 Nm (53 lb-in). 5. Remove and discard the O-ring seal. 6. CAUTION: Use an O-ring seal made of special fuel resistant material. Use of an ordinary O-ring seal can cause the fuel system to leak. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 916 Do not reuse the O-ring seal. To install, reverse the removal procedure. Lubricate the new O-ring seal with clean engine oil. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 View 151-11 (behind Dash Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 920 C282 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 921 Inertia Fuel Shutoff Switch: Description and Operation INERTIA FUEL SHUTOFF (IFS) SWITCH Typical Inertia Fuel Shutoff (IFS) Switch The IFS switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shutoff 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's Literature for the location of the IFS. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 922 Inertia Fuel Shutoff Switch: Service and Repair INERTIA FUEL SHUTOFF (IFS) SWITCH Removal and Installation 1. NOTE: The front passenger door frame scuff plate is retained only by internal metal clips. Remove the front passenger door frame scuff plate. 2. NOTE: - The front passenger door side interior kick panel is retained only by internal metal clips. - It may be necessary to reposition the lower end of the door jam weather stripping to remove the front passenger door side interior kick panel. Remove the front passenger side interior kick panel. 3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Remove the bolts and the IFS switch - To install, tighten to 2 Nm (18 lb-in). 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 926 C189 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Electronic Throttle Body (ETB) Position Sensor Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR The ETB position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB position signals are required for increased monitoring. The first ETB position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). During normal operation the negative slope ETB position sensor signal (TP1) is used by the control strategy as the indication of throttle position. The 2 ETB position sensor signals make sure the PCM receives a correct input even if 1 signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Electronic Throttle Body (ETB) Position Sensor > Page 929 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor THROTTLE POSITION (TP) SENSOR Typical TP Sensor The TP sensor 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 3-blade electrical connector that may be gold plated. The gold plating increases the corrosion resistance on the terminals and increases the connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM from the TP. The operating 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) - throttle angle rate Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 930 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Removal Vehicles equipped with a 4.6L (3V) engine 1. Remove the air cleaner outlet pipe. 2. Remove the bolts and position the heated positive crankcase ventilation (PCV) fitting and hoses aside. - Remove and discard the O-ring seal. All vehicles 3. Disconnect the throttle position (TP) sensor electrical connector. 4. CAUTION: Failure to remove the TP sensor screws in the following manner will result in damage to the screws. First loosen the screws 1-2 full turns using a hand tool and then use a suitable high-speed driver to complete the removal. Remove and discard the 2 screws and the TP sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 931 Installation All vehicles 1. CAUTION: - Do not reuse the TP sensor and screws. A new TP sensor and screws must be installed. - Do not use a high-speed driver to install the new screws or damage to the TP sensor can occur. NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor is aligned with the radial locator hole on the throttle body. Position the new TP sensor and install the 2 new screws. Tighten to 3 Nm (27 lb-in). 2. Connect the TP sensor electrical connector. Vehicles equipped with a 4.6L (3V) engine 3. Install a new O-ring seal, position the heated PCV fitting and install the bolts. 4. Install the air cleaner outlet pipe. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor C180 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 938 C1366 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 939 C1367 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 940 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR Typical Synchronizer Hall-Effect CMP Sensor Typical Variable Reluctance CMP Sensor The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to select the correct ignition coil to fire. Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor and the 2-pin connector variable reluctance type sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 941 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation 1. Disconnect the camshaft position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. - To install, tighten to 6 Nm (53 lb-in). 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 945 Crankshaft Position Sensor: Diagrams C101 C1120 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 946 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Typical Crankshaft Position (CKP) Sensor The 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 PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L 10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor 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 a fixed reference for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid deceleration between teeth. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 947 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). 4. NOTE: Be sure the sensor wiring is routed away from the battery cable. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER Removal and Installation NOTE: - When any new lock cylinder is installed, the driver door and ignition lock cylinders should be installed as a set. This eliminates carrying an extra key which fits only 1 lock. If a new key is used, 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. With the ignition switch in the ON position, press the locking pin with a suitable tool and remove the ignition lock cylinder. 2. To install, reverse the removal procedure. - Lubricate the ignition lock cylinder during installation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 955 C108 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 956 Knock Sensor: Description and Operation KNOCK SENSOR (KS) Two Types Of Knock Sensor (KS) The KS 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 957 Knock Sensor: Service and Repair KNOCK SENSOR (KS) Removal and Installation 1. Remove the intake manifold. 2. Disconnect the knock sensor (KS) electrical connector. 3. Remove the bolt and the KS. - To install, tighten to 20 Nm (15 lb-ft). 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor, Left/Right View 151-1 (Engine Compartment - 4.0L, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor, Left/Right > Page 963 View 151-15 (Left Rear, (1 0f 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor, Left/Right > Page 964 View 151-17 (Right Rear, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor, Left/Right > Page 965 View 151-21 (Driver Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor, Left/Right > Page 966 View 151-22 (Passenger Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver Side Impact Sensor: Diagrams Side Impact Sensor, Driver Side C567A C567B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver Side > Page 969 Impact Sensor: Diagrams Side Impact Sensor, Passenger Side C644A C644B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver Side > Page 970 C1465 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver Side > Page 971 C1466 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver Side > Page 972 Impact Sensor: Diagrams C567A C567B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver Side > Page 973 C644A C644B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver Side > Page 974 C1465 C1466 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver Side > Page 975 C3248 C3249 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Page 976 Impact Sensor: Description and Operation SENSORS WARNING: - The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, a new RCM must be installed whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. - Vehicle sensor orientation is critical for correct restraint system operation. If a vehicle equipped with an SRS is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and correctly position the sensor or any other damaged SRS components whether or not the air bag is deployed. For these vehicles, the SRS uses up to 6 satellite sensors in addition to the RCM. The RCM is mounted to the center tunnel beneath the console. All vehicles will have 2 front impact severity sensors located in the front-center area of the vehicle, behind the grille mounted on the lower radiator support. The first row impact sensors are located in each of the front doors behind the trim panel. If the vehicle is equipped with safety canopies, there are 2 additional side impact sensors. The 2 additional sensors are located on each C-pillar. Mounting orientation and torque is critical for correct operation of all impact and rollover sensors. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor Impact Sensor: Service and Repair Front Impact Severity Sensor FRONT IMPACT SEVERITY SENSOR 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. - 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. Install and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To reduce the risk of personal injury, do not use any memory saver devices. 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. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 979 - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. Depower the system. 2. Remove the 4 pin-type retainers and the lower radiator air deflector. 3. WARNING: The tightening torque of the air bag front impact severity sensor retaining nuts is critical for correct system operation. NOTE: Make sure the radiator support and front impact severity sensor mating surfaces are clean and free of foreign material. - Note position of locator tab on sensor bracket for installation. Remove the front impact severity sensor bolt. - To install, tighten to 12 Nm (9 lb-ft). 4. Disconnect the front impact severity sensor electrical connector and remove the sensor. 5. To install, reverse the removal procedure. 6. Repower the system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 980 Impact Sensor: Service and Repair Side Impact Sensor C-Pillar SIDE IMPACT SENSOR - C-PILLAR Removal and 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. - Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air bag SRS is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Install a new sensor and correctly position the sensor or any other damaged SRS components whether or not the air bag is deployed. - To reduce the risk of personal injury, do not use any memory saver devices. 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 SRS fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 981 - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - The LH and RH C-pillar mounted side impact sensors are not interchangeable. 1. Depower the system. 2. Remove the rear door scuff plate. 3. NOTE: Make sure the safety belt webbing is not twisted prior to installation. Remove the bolt and the safety belt anchor. To install, tighten to 40 Nm (30 lb-ft). 4. Detach the upper C-pillar trim panel and position aside. 5. Position aside the quarter trim panel. - Pull out on the quarter trim panel at the C-pillar to release the retaining clips and access the C-pillar side impact sensor. 6. Disconnect the side impact sensor electrical connector. 7. WARNING: The tightening torque of the air bag side impact sensor retaining bolts is critical for correct system operation. NOTE: Note the position of the sensor and bracket locating tab for installation. - Make sure the C-pillar and side impact severity sensor mating surfaces are clean and free of foreign material. Remove the 2 bolts and the side impact sensor and bracket assembly. To install, tighten to 12 Nm (9 lb-ft). 8. To install, reverse the removal procedure. 9. Repower the system. Front Door SIDE IMPACT SENSOR - FRONT DOOR Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 982 Removal and 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. - Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air bag SRS is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Install a new sensor and correctly position the sensor or any other damaged SRS components whether or not the air bag is deployed. - To reduce the risk of personal injury, do not use any memory saver devices. 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 SRS fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - Driver side shown, passenger side similar. 1. Depower the system. 2. Remove the front interior door trim panel. 3. Detach the rearward lower corner of the watershield on the door to expose the side impact sensor. 4. Disconnect the side impact sensor electrical connector. 5. WARNING: The tightening torque of the side impact sensor retaining bolt is critical for correct system operation. CAUTION: The ground wire must be placed between the bolt head and the sensor. Never position the ground wire between the U-nut Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 983 and the sensor. NOTE: Make sure the side impact sensor mating surfaces are clean and free of foreign material. - Note the position of the side impact sensor locating tabs for installation. Remove the bolt and the side impact sensor. To install, tighten to 9 Nm (80 lb-in). 6. To install, reverse the removal procedure. 7. Repower the system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger View 151-20 (Passenger Seat) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger > Page 988 View 151-19 (Driver Seat) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver C3065 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver > Page 991 C3066 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Page 992 Seat Belt Buckle Switch: Description and Operation SAFETY BELT BUCKLE SWITCHES As part of the SRS, the front safety belt buckles are equipped with safety belt buckle switches. The safety belt buckle switches are comprised of integrated circuits called Hall-effect sensors. The safety belt buckle switches (Hall-effect sensors) are located in the driver and front passenger safety belt buckles. The safety belt buckle switches indicate to the RCM whether the safety belts are buckled or unbuckled. The RCM uses this information in determining the deployment rate of the dual-stage driver and passenger air bag modules. The RCM also communicates the driver safety belt buckle switch status to the instrument cluster module, which monitors the information to control the safety belt warning indicator. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Tower Position Sensor > Component Information > Description and Operation Seat Belt Tower Position Sensor: Description and Operation SEAT TRACK POSITION SENSOR The seat track position sensor is a Hall-effect sensor located on the driver seat track. The seat track position sensor informs the RCM of the driver seat position. Based on programmed limits, the seat track position sensor will inform the RCM of the driver seat position. The RCM uses this information in determining the deployment rate of the dual-stage driver air bag module. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Locations > Occupant Classification Sensor (OCS) Module View 151-20 (Passenger Seat) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Locations > Occupant Classification Sensor (OCS) Module > Page 1000 View 151-20 (Passenger Seat) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams > Occupant Classification Sensor (OCS) Module C3159 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams > Occupant Classification Sensor (OCS) Module > Page 1003 C3291 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams > Occupant Classification Sensor (OCS) Module > Page 1004 C3292 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Description and Operation > OCS System Seat Occupant Sensor: Description and Operation OCS System OCS System The OCS system is found only on the front passenger seat. The front passenger OCS system is comprised of the following: 2 OCS rails (weight sensors) that are mounted to each side of the seat track; an OCS module (electronic control unit) which is mounted to the electrical bracket underneath the seat cushion pan. The weight of any occupant or object on the front passenger seat is electronically communicated to the OCS module. The OCS system is also used for operation of the passenger Belt Minder. To deactivate or reactivate the passenger Belt Minder feature, refer to Seat Belt Systems or the owner's literature. The components that make up the OCS system, OCS module, inboard OCS rail and outboard OCS rail are serviced separately. When the front passenger seat is removed for service, the Zero Seat Weight Test must be carried out after the installation of the front passenger seat. When a OCS system component is installed new, the System Reset must be carried out after the installation of the front passenger seat. The Zero Seat Weight Test and/or System Reset must be carried out only as instructed to do so. OCS Rails (Weight Sensors) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Description and Operation > OCS System > Page 1007 The components that make up the OCS system (OCS system module, inboard OCS rail and outboard OCS rail) are serviced separately. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Description and Operation > OCS System > Page 1008 Seat Occupant Sensor: Description and Operation Occupant Classification Sensor (OCS) System OCCUPANT CLASSIFICATION SENSOR (OCS) SYSTEM The occupant classification system (OCS) system is standard equipment on all front passenger seats. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Description and Operation > Page 1009 Seat Occupant Sensor: Service and Repair OCCUPANT CLASSIFICATION SENSOR Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Description and Operation > Page 1010 Part 2 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. - The occupant classification sensor rails have a built-in strain gauge which may operate incorrectly if an occupant classification sensor rail is dropped by itself, dropped when installed to the front passenger seat or dropped when installed to a front passenger seat track assembly. Use care when handling an occupant classification sensor rail or when installed to the front passenger seat of front passenger seat track assembly. Failure to follow these instructions may increase the risk of personal injury or death in a crash. - Do not disassemble the occupant classification sensor rail, tighten or loosen any of the nuts and bolts installed to the occupant classification sensor rail body. Only the 8 bolts that attach the 2 occupant classification sensor rails to the seat track should be removed and installed. Failure to follow these instructions may increase the risk of personal injury or death in a crash. - Oil, grease, water or foreign material on or in the occupant classification sensor rail may cause the supplemental restraint system to deploy incorrectly. Never allow oil, grease, water or foreign material to get on or into the occupant classification sensor rail. Failure to follow these instructions may increase the risk of personal injury or death in a crash. - To reduce the risk of personal injury, do not use any memory saver devices. 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: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - 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. - Outboard occupant classification sensor (OCS) rail shown, inboard similar. 1. Remove the passenger seat and depower the system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Description and Operation > Page 1011 2. CAUTION: Push only on the tip of the occupant classification sensor (OCS) electrical connector release tab to release the electrical connector. Do not insert the tool too deep into the OCS electrical connector or damage to the electrical connector may occur. NOTE: Note the position and the routing of the OCS rail electrical wiring, connector and wiring retainers for installation. On the affected side, detach the 2 OCS rail wiring retainers. Then using a suitable tool, release the tab and disconnect the OCS rail electrical connector. 3. If equipped, disconnect the power seat track motor electrical connector. 4. Move the seat to the forward most position. - If equipped with a power seat track, apply power and ground to the pins shown. 5. Remove the 2 rear bolts from the affected OCS rail. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Description and Operation > Page 1012 6. Move the seat to the rearward most position. - If equipped with a power seat track, apply power and ground to the pins shown. 7. NOTE: Note the position of where the locator tab on the OCS rail goes through the OCS rail shield and into the rear mounting point of the seat track for installation. Remove the 2 front bolts and the affected OCS rail and shield. Installation NOTE: If installing a new seat track, position the seat track where the seat will be in the rearward most position before starting installation of the OCS rails. 1. WARNING: The occupant classification sensor rail shield is an aid to prevent foreign material and contaminants from entering the occupant classification sensor rail. Make sure the occupant classification sensor rail shield is present, is not damaged and is correctly installed to the occupant classification sensor rail. Failure to follow these instructions may increase the risk of personal injury or death in a crash. NOTE: Make sure the OCS rail shield is seated correctly on the OCS rail. Align the locator tab to the shield. Position the OCS rail shield on the OCS rail. Then position the OCS rail and shield on the seat track while noting the correct installation of the OCS rail locator tab into the seat track. 2. NOTE: To make sure of correct installation, the OCS rail bolts must be installed in the sequence shown. While holding the OCS rail and shield firmly in position, install the OCS rail front mounting position rear bolt. Tighten to 25 Nm (18 lb-ft). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Description and Operation > Page 1013 3. While still holding the OCS rail and shield firmly in position, install the OCS rail front mounting position front bolt. - Tighten to 25 Nm (18 lb-ft). 4. Move the seat to the forward most position. - If equipped with a power seat track, apply power and ground to the pins shown. 5. Install the 2 rear OCS rail bolts. - Tighten to 25 Nm (18 lb-ft). 6. NOTE: Make sure to route the OCS rail wiring and install the 2 wiring retainers as noted during removal. Connect the OCS rail electrical connector. Then route the OCS rail wiring and attach the 2 wiring retainers. 7. Center the seat track to the seat cushion pan. - If equipped with a power seat track, apply power and ground to the pins shown. 8. If equipped, connect the power seat track motor electrical connector. 9. Install the passenger seat and repower the supplemental restraints system (SRS). Do not prove out the SRS at this time. 10. Carry out the appropriate procedure after installation of an OCS system component. - If installing the original OCS system component, carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. See: Restraint Systems/Air Bag Systems/Testing and Inspection/Component Tests and General Diagnostics/Occupant Classification Sensor (OCS) System Zero Seat Weight Test - If installing a new OCS system component, carry out the Occupant Classification Sensor (OCS) System Reset procedure and prove out the SRS. See: Restraint Systems/Air Bag Systems/Service and Repair Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Service and Repair Seat Position Sensor: Service and Repair SEAT POSITION SENSOR Removal and 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a SRS component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a SRS fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - Power seat track seat position sensor shown, manual seat track position sensor similar. 1. Position the front seat to the rearmost and upward position. 2. Depower the system. 3. Disconnect the seat position sensor electrical connector. 4. WARNING: The tightening torque of the seat position sensor retaining bolt is critical for correct system operation. NOTE: Note the position of the seat position sensor locating tab for installation. Remove the bolt and the seat position sensor. To install, tighten to 6 Nm (53 lb-in). 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Service and Repair > Page 1017 6. Repower the system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations View 151-19 (Driver Seat) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 1021 C356 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER Removal and Installation NOTE: - When any new lock cylinder is installed, the driver door and ignition lock cylinders should be installed as a set. This eliminates carrying an extra key which fits only 1 lock. If a new key is used, 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. With the ignition switch in the ON position, press the locking pin with a suitable tool and remove the ignition lock cylinder. 2. To install, reverse the removal procedure. - Lubricate the ignition lock cylinder during installation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Recalls: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement Technical Service Bulletin # 09B11 Date: 100115 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on January 15, 2010. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Recalls: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 1035 FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website on January 15, 2010. Owner names and addresses will be available on January 31, 2010. 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 program 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 field service action. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected customers whose vehicles are not on your VIN list 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 service action. 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 service action 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 ^ Ford Motor Company will only refund owner-paid repairs covered by this program if the repair was performed before the date of the Owner Notification Letter. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ If a "stuck in park" event occurs, customers can override the brake shift interlock with information located in the Owner Guide. The 09B11 Owner Letter provides directions to locate the override information and includes a representative brake shift interlock owner guide attachment. There should be no emergency repair refunds after the customer mailings are complete. ^ Refunds will only be provided for the cost associated with the diagnosis and replacement of the transmission gearshift lever due to a "stuck in park" concern. ^ 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. ^ The refund period for repairs performed prior to the date of the Owner Notification Letter will expire on July 31, 2010. ^ Refund Claiming Information (submit on separate repair line). - Program Code: 09B11 - 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 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Recalls: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 1036 ^ 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 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. ^ Refer to ACESII manual for claims preparation and submission information. ^ PROGRAM TERMS: This program will be in effect until January 31, 2011 regardless of mileage. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this recall is 50415. DEALER PRICE For latest prices, 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 In some of the affected vehicles, the transmission gearshift lever may not move out of the park position even when the brake pedal is depressed. This "stuck in park" condition can develop due to silicon dioxide contamination building up on the contacts of the park detect switch located on the transmission gearshift lever. SERVICE PROCEDURE 1. Remove the front floor console. Refer to the appropriate WSM Section 501-12 Console - Front. 2. NOTICE: Electronic modules are sensitive to static electrical charges If the new circuit board is exposed to these charges, damage may result The circuit board should be handled by the plastic connector(s) and avoid touching any of the metal surfaces. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Recalls: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 1037 Disconnect the three electrical connectors from the white circuit board that is located on the lower RH section of the transmission gearshift lever See Figure 1. 3. Remove the circuit board case from the RH side of the transmission gearshift lever by releasing the two retainer clips See Figure 2. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Recalls: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 1038 4. Replace the circuit board See Figure 3. ^ Separate the upper circuit board case cover from the lower case containing the circuit board. ^ Remove and discard the circuit board Install the new circuit board. Snap the upper circuit board case cover and the lower case back together. 5. To reinstall the circuit board case, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Recalls: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 1039 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Recalls: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 1040 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Recalls: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 1041 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets Instrument Panel Control Module: All Technical Service Bulletins Instruments - Trip Odometers/Fuel Economy Resets TSB 09-21-7 11/02/09 TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS UNINTENTIONALLY FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally. This condition may occur if there is an intermittent electrical connection on the power feed to the cluster or if the reset button on the 3-button message center assembly is momentarily touched. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. With the key in the On position, display the trip odometer mileage. 2. Start the vehicle. 3. Cycle the key back Off and restart the vehicle. 4. Verify whether the trip mileage reset or not. 5. If not, proceed to Step 10. 6. If it reset, turn the key Off and remove the key from the ignition. 7. Activate the emergency flashers. 8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal fuse and wiring diagnostics to correct the power feed circuit. 9. Verify repair and proceed to Step 10. 10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release 63.07 and higher. This new calibration is not included in the VCM 2009.9 DVD. Calibration files may also be obtained at the website. NOTE REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT RESOLVE THIS ISSUE. 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 092107A 2006-2010 Explorer, 0.3 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 1047 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Neutral Safety Switch: > 09-21-7 > Nov > 09 > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement Technical Service Bulletin # 09B11 Date: 100115 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on January 15, 2010. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Neutral Safety Switch: > 09-21-7 > Nov > 09 > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 1057 FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website on January 15, 2010. Owner names and addresses will be available on January 31, 2010. 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 program 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 field service action. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected customers whose vehicles are not on your VIN list 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 service action. 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 service action 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 ^ Ford Motor Company will only refund owner-paid repairs covered by this program if the repair was performed before the date of the Owner Notification Letter. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ If a "stuck in park" event occurs, customers can override the brake shift interlock with information located in the Owner Guide. The 09B11 Owner Letter provides directions to locate the override information and includes a representative brake shift interlock owner guide attachment. There should be no emergency repair refunds after the customer mailings are complete. ^ Refunds will only be provided for the cost associated with the diagnosis and replacement of the transmission gearshift lever due to a "stuck in park" concern. ^ 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. ^ The refund period for repairs performed prior to the date of the Owner Notification Letter will expire on July 31, 2010. ^ Refund Claiming Information (submit on separate repair line). - Program Code: 09B11 - 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 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Neutral Safety Switch: > 09-21-7 > Nov > 09 > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 1058 ^ 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 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. ^ Refer to ACESII manual for claims preparation and submission information. ^ PROGRAM TERMS: This program will be in effect until January 31, 2011 regardless of mileage. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this recall is 50415. DEALER PRICE For latest prices, 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 In some of the affected vehicles, the transmission gearshift lever may not move out of the park position even when the brake pedal is depressed. This "stuck in park" condition can develop due to silicon dioxide contamination building up on the contacts of the park detect switch located on the transmission gearshift lever. SERVICE PROCEDURE 1. Remove the front floor console. Refer to the appropriate WSM Section 501-12 Console - Front. 2. NOTICE: Electronic modules are sensitive to static electrical charges If the new circuit board is exposed to these charges, damage may result The circuit board should be handled by the plastic connector(s) and avoid touching any of the metal surfaces. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Neutral Safety Switch: > 09-21-7 > Nov > 09 > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 1059 Disconnect the three electrical connectors from the white circuit board that is located on the lower RH section of the transmission gearshift lever See Figure 1. 3. Remove the circuit board case from the RH side of the transmission gearshift lever by releasing the two retainer clips See Figure 2. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Neutral Safety Switch: > 09-21-7 > Nov > 09 > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 1060 4. Replace the circuit board See Figure 3. ^ Separate the upper circuit board case cover from the lower case containing the circuit board. ^ Remove and discard the circuit board Install the new circuit board. Snap the upper circuit board case cover and the lower case back together. 5. To reinstall the circuit board case, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Neutral Safety Switch: > 09-21-7 > Nov > 09 > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 1061 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Neutral Safety Switch: > 09-21-7 > Nov > 09 > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 1062 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Neutral Safety Switch: > 09-21-7 > Nov > 09 > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 1063 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement Technical Service Bulletin # 09B11 Date: 100115 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on January 15, 2010. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 1069 FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website on January 15, 2010. Owner names and addresses will be available on January 31, 2010. 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 program 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 field service action. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected customers whose vehicles are not on your VIN list 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 service action. 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 service action 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 ^ Ford Motor Company will only refund owner-paid repairs covered by this program if the repair was performed before the date of the Owner Notification Letter. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ If a "stuck in park" event occurs, customers can override the brake shift interlock with information located in the Owner Guide. The 09B11 Owner Letter provides directions to locate the override information and includes a representative brake shift interlock owner guide attachment. There should be no emergency repair refunds after the customer mailings are complete. ^ Refunds will only be provided for the cost associated with the diagnosis and replacement of the transmission gearshift lever due to a "stuck in park" concern. ^ 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. ^ The refund period for repairs performed prior to the date of the Owner Notification Letter will expire on July 31, 2010. ^ Refund Claiming Information (submit on separate repair line). - Program Code: 09B11 - 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 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 1070 ^ 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 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. ^ Refer to ACESII manual for claims preparation and submission information. ^ PROGRAM TERMS: This program will be in effect until January 31, 2011 regardless of mileage. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this recall is 50415. DEALER PRICE For latest prices, 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 In some of the affected vehicles, the transmission gearshift lever may not move out of the park position even when the brake pedal is depressed. This "stuck in park" condition can develop due to silicon dioxide contamination building up on the contacts of the park detect switch located on the transmission gearshift lever. SERVICE PROCEDURE 1. Remove the front floor console. Refer to the appropriate WSM Section 501-12 Console - Front. 2. NOTICE: Electronic modules are sensitive to static electrical charges If the new circuit board is exposed to these charges, damage may result The circuit board should be handled by the plastic connector(s) and avoid touching any of the metal surfaces. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 1071 Disconnect the three electrical connectors from the white circuit board that is located on the lower RH section of the transmission gearshift lever See Figure 1. 3. Remove the circuit board case from the RH side of the transmission gearshift lever by releasing the two retainer clips See Figure 2. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 1072 4. Replace the circuit board See Figure 3. ^ Separate the upper circuit board case cover from the lower case containing the circuit board. ^ Remove and discard the circuit board Install the new circuit board. Snap the upper circuit board case cover and the lower case back together. 5. To reinstall the circuit board case, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 1073 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 1074 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 1075 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets Instrument Panel Control Module: Customer Interest Instruments - Trip Odometers/Fuel Economy Resets TSB 09-21-7 11/02/09 TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS UNINTENTIONALLY FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally. This condition may occur if there is an intermittent electrical connection on the power feed to the cluster or if the reset button on the 3-button message center assembly is momentarily touched. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. With the key in the On position, display the trip odometer mileage. 2. Start the vehicle. 3. Cycle the key back Off and restart the vehicle. 4. Verify whether the trip mileage reset or not. 5. If not, proceed to Step 10. 6. If it reset, turn the key Off and remove the key from the ignition. 7. Activate the emergency flashers. 8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal fuse and wiring diagnostics to correct the power feed circuit. 9. Verify repair and proceed to Step 10. 10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release 63.07 and higher. This new calibration is not included in the VCM 2009.9 DVD. Calibration files may also be obtained at the website. NOTE REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT RESOLVE THIS ISSUE. 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 092107A 2006-2010 Explorer, 0.3 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 1083 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets Instrument Panel Control Module: All Technical Service Bulletins Instruments - Trip Odometers/Fuel Economy Resets TSB 09-21-7 11/02/09 TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS UNINTENTIONALLY FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally. This condition may occur if there is an intermittent electrical connection on the power feed to the cluster or if the reset button on the 3-button message center assembly is momentarily touched. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. With the key in the On position, display the trip odometer mileage. 2. Start the vehicle. 3. Cycle the key back Off and restart the vehicle. 4. Verify whether the trip mileage reset or not. 5. If not, proceed to Step 10. 6. If it reset, turn the key Off and remove the key from the ignition. 7. Activate the emergency flashers. 8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal fuse and wiring diagnostics to correct the power feed circuit. 9. Verify repair and proceed to Step 10. 10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release 63.07 and higher. This new calibration is not included in the VCM 2009.9 DVD. Calibration files may also be obtained at the website. NOTE REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT RESOLVE THIS ISSUE. 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 092107A 2006-2010 Explorer, 0.3 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 1089 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Component Information > Specifications Shift Solenoid: Specifications Solenoid Operation Chart Solenoid Operation Chart Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Component Information > Diagrams > Diagram Information and Instructions > Page 1094 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Component Information > Diagrams > Diagram Information and Instructions > Page 1095 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Component Information > Diagrams > Diagram Information and Instructions > Page 1096 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Component Information > Diagrams > Diagram Information and Instructions > Page 1097 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Component Information > Diagrams > Diagram Information and Instructions > Page 1098 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Component Information > Diagrams > Diagram Information and Instructions > Page 1099 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Component Information > Diagrams > Diagram Information and Instructions > Page 1100 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Component Information > Diagrams > Diagram Information and Instructions > Page 1101 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Component Information > Diagrams > Diagram Information and Instructions > Page 1102 Shift Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Component Information > Diagrams > Diagram Information and Instructions > Page 1103 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Component Information > Diagrams > Diagram Information and Instructions > Page 1104 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Component Information > Diagrams > Diagram Information and Instructions > Page 1105 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Component Information > Diagrams > Diagram Information and Instructions > Page 1106 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Component Information > Diagrams > Diagram Information and Instructions > Page 1107 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Component Information > Diagrams > Diagram Information and Instructions > Page 1108 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Component Information > Diagrams > Diagram Information and Instructions > Page 1109 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Component Information > Diagrams > Diagram Information and Instructions > Page 1110 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Component Information > Diagrams > Page 1111 Shift Solenoid: Testing and Inspection Pinpoint Tests - OSC Equipped Vehicle Special Tool(s) (Part 1) Special Tool(s) (Part 2) Shift Solenoid Pre-Diagnosis Any time an electrical connector or solenoid body is disconnected, inspect the connector for terminal condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install new as necessary. Use this shift solenoid operation information when carrying out Pinpoint Test A. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Component Information > Diagrams > Page 1112 Solenoid Operation Chart (Part 1) Solenoid Operation Chart (Part 2) Shift Solenoid Failure Mode Chart Failed ON or OFF due to powertrain control module (PCM) and/or vehicle wiring concerns, solenoid electrically, mechanically or hydraulically stuck ON or OFF. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Component Information > Diagrams > Page 1113 SSA, SSB SSC, SSD Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Component Information > Diagrams > Page 1114 PC A, PC B, PC C (Part 1) PC A, PC B, PC C (Part 2) PC A, PC B, PC C (Part 3) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Component Information > Diagrams > Page 1115 Shift Solenoid: Service and Repair Solenoid Body Assembly Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the drain plug and drain the fluid. 3. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. Disconnect the solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the gasket should be reused. Remove the 16 transmission fluid pan screws, fluid pan and gasket. 5. Remove the transmission fluid filter. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Component Information > Diagrams > Page 1116 6. CAUTION: Do not damage the solenoid body connector pins. Remove the solenoid body bolts and remove the solenoid body by pulling down on the solenoid body and pushing down on the connector from the other side of the case. Installation 1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean automatic transmission fluid. 2. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur. Install the solenoid body. Tighten the bolts in sequence shown. ^ Tighten to 8 Nm (71 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Component Information > Diagrams > Page 1117 3. CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be damaged. NOTE: Make sure that the fluid filter seals are correctly seated on the filter. Lubricate the seals and install the transmission fluid filter. ^ Tighten to 10 Nm (89 inch lbs.) 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage, if not damaged, the gasket should be reused. Install the transmission fluid pan and gasket and loosely install the screws. 5. Tighten the screws in a crisscross sequence. ^ Tighten to 11 Nm (8 ft. lbs.) 6. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the specification. NOTE: Always install new O-ring seals on vehicle harness connector. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission connector and connect the connector. ^ Tighten to 5 Nm (44 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Component Information > Diagrams > Page 1118 7. Fill the transmission. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations View 151-2 (Engine Compartment - 4.0L, (2 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 1124 C121 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch POWER STEERING PRESSURE (PSP) SWITCH Typical Power Steering Pressure (PSP) Switch The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch > Page 1127 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor POWER STEERING PRESSURE (PSP) SENSOR Typical Power Steering Pressure (PSP) Sensor The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM changes as the hydraulic pressure changes. The PCM uses the input signal from the PSP sensor to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP sensor signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example, during parking maneuvers. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 1131 C226 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 1136 C226 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Special Tool(s) NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the Smart Junction Box (SJB). NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire Pressure Monitoring System (TPMS). Radio frequency noise is generated by electrical motors and appliance operation, cellular telephones, remote transmitters, power inverters and portable entertainment equipment. NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor again. NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire procedure must be repeated. NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for front and rear tires, tire rotation will not affect the system. 1. Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. - The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire Pressure Monitor Activation Tool must remain in place 180 degrees from the valve stem. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 1141 6. Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press and release the test button on the Tire Pressure Monitor Activation Tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB. 7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF tire sidewall opposite (180 degrees) from the valve stem and press and release the test button to train the RF tire pressure sensor. NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and the entire procedure must be repeated. 8. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor identifiers trained to the SJB and document them on the applicable warranty claim. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed SJB. 10. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and carry out the SJB On-Demand Self Test. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Disassembly CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor can be removed and installed without removing the strap or the cradle. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. 1. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. 2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip can occur. Using a pocket screwdriver, or similar tool, remove the sensor locking clip. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1144 3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor can occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. 4. Remove the sensor. Assembly 1. CAUTION: Damage to the sensor can occur if excessive force is applied during sensor installation. NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise when correctly seated. Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the sensor locking clip cannot be fully inserted, then the sensor may not be fully seated on the cradle or the locking clip may be inserted backward. Insert a new locking clip into the sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1145 3. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Training. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1146 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Material Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1147 Disassembly CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There are several different strap kits available based on wheel diameter but all strap kits share the same base part number. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. 1. Remove the tire pressure monitoring system (TPMS) sensor. 2. WARNING: The TPMS band is under tension. Always use safety goggles or a face shield and gloves when removing the TPMS band/strap. Failure to follow these instructions may result in personal injury. Remove a factory installed strap in this sequence: 1 Locate the strap buckle and secure the strap to the wheel using duct tape or a similar item, on both sides of the buckle approximately 25 mm (0.98 inch) from the buckle. 2 Using a large screwdriver and a twisting motion, unbuckle the strap. 3 Discard the strap. To remove a dealer installed strap, turn the worm gear screw until the strap is fully released from the worm gear. ^ Discard the strap. 3. NOTE: To aid assembly, mark the location of the cradle prior to disassembly. Using a screwdriver, or similar tool, remove the cradle by inserting the screwdriver under the cradle and prying up. Assembly 1. NOTE: Make sure the sensor is fully seated into the new cradle. The sensor will make a "click" noise when fully seated. Position the sensor into the new cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. CAUTION: Metal scrapers can damage the wheel. Use only plastic or non-metallic scrapers to remove the cradle adhesive strip residue. NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the valve stem. Clean the area where the sensor and cradle are to be installed. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1148 3. NOTE: The sensor and cradle must be positioned with the hinge side of the sensor on the RH side when viewed from the curb side (beauty side) of the wheel. NOTE: The sensor has raised markings indicating how to position the sensor. Remove the adhesive tape liner from the cradle and position the sensor and cradle into the wheel drop well 180° from the valve stem. 4. Install the tapered end of the strap through the opening of the cradle on the hinge side of the sensor. This will position the worm gear on the locking clip side of the sensor. 5. CAUTION: Steel wheels have a "high spot" along their circumference. Make sure the strap is positioned in the lowest spot possible for correct sensor and cradle retention. NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear. Position the worm gear 13 - 26 mm (0.5 - 1.0 inch) away from the sensor and tighten the worm gear. ^ Tighten to 3 Nm (27 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1149 6. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Training. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions Brake Switch - TCC: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1156 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1157 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1158 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1159 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1160 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1161 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1162 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1163 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1164 Brake Switch - TCC: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1165 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1166 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1167 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1168 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1169 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1170 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1171 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 1172 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Page 1173 Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Overdrive Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1178 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1179 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1180 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1181 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1182 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1183 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1184 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1185 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1186 Overdrive Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1187 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1188 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1189 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1190 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1191 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1192 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1193 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1194 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor/Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1199 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1200 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1201 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1202 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1203 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1204 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1205 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1206 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1207 Throttle Position Sensor/Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1208 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1209 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1210 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1211 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1212 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1213 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1214 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1215 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Mode Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1220 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1221 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1222 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1223 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1224 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1225 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1226 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1227 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1228 Transmission Mode Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1229 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1230 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1231 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1232 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1233 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1234 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1235 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1236 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Control (TC) Switch Transmission Mode Switch: Description and Operation Transmission Control (TC) Switch Transmission Control (TC) Switch The transmission control (TC) switch is a momentary contact switch located on the selector lever knob. Pushing the TC switch will either disengage or engage the overdrive function of the transmission. If OVERDRIVE is disengaged, the message O/D OFF will illuminate on the instrument panel. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Control (TC) Switch > Page 1239 Transmission Mode Switch: Description and Operation Transmission Control Switch (TCS) TRANSMISSION CONTROL SWITCH (TCS) Typical Transmission Control Switch (TCS) Typical Transmission Control Switch (TCS) The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature, the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage overdrive. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Page 1240 Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch Removal 1. Remove the transmission selector lever knob. 2. Remove the transmission control switch from the knob. Installation 1. Install the transmission control switch into the knob. 2. Install the transmission selector lever knob. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1246 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1247 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1248 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1249 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1250 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1251 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1252 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1253 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1254 Transmission Position Switch/Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1255 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1256 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1257 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1258 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1259 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1260 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1261 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1262 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1263 C167 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1264 Transmission Position Switch/Sensor: Testing and Inspection Digital Transmission Range (TR) Sensor Diagnosis Chart Digital Transmission Range (TR) Sensor Diagnosis Chart Wiggle Test Information for Open/Shorts ^ TR4, TR3A, TR2 and TR1 are all closed in PARK. PARK is a good position to check for intermittent open circuits (with scan tool monitoring TRD). ^ TR4, TR3A, TR2 and TR1 are all open in OVERDRIVE, so OVERDRIVE is a good position to check for shorts to ground. To determine the shorted components while observing TRD, unplug the TR and determine if the short goes away. If the short is still present unplug the transmission harness and determine if the short goes away. If the short is still present, then the short is in the PCM or vehicle harness. Remove the suspect circuit(s) wire terminal from the PCM connector. If the short is still present, then the PCM has an internal failure, otherwise the failure is in the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1265 Transmission Position Switch/Sensor: Adjustments Transmission Range (TR) Sensor Adjustment Special Tool(s) Adjust 1. With the vehicle in NEUTRAL, position it on a hoist For additional information, refer to Maintenance/Service and Repair. 2. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the connector. 4. Disconnect the digital transmission range (TR) sensor electrical connector. 5. Remove the range selector lever cable end from the manual control lever. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1266 6. Remove the outer manual control lever. 7. Loosen but do not remove the digital TR sensor screws. 8. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. ^ Tighten to 8 Nm (71 inch lbs.) 9. Install the outer manual lever. ^ Tighten to 48 Nm (35 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1267 10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable end onto the manual control lever. 11. Reconnect the digital TR sensor electrical connector. 12. Move the rubber boot back over the connector. 13. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1268 14. Verify that the selector lever cable is adjusted correctly. 15. Verify that the vehicle will start in PARK and NEUTRAL and that the reverse lamps illuminate in REVERSE. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1269 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the connector. 4. Disconnect the digital transmission range (TR) sensor electrical connector. 5. Remove the selector lever cable from the manual control lever. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1270 6. Remove the outer manual control lever. 7. Remove the digital TR sensor. Installation 1. CAUTION: The digital transmission range sensor must fit flush against the boss on the case to prevent damage to the sensor. Install the digital TR sensor and 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 be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1271 ^ Tighten to 8 Nm (71 inch lbs.) 3. Install the outer manual lever. ^ Tighten to 48 Nm (35 ft. lbs.) 4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable to the manual control lever. 5. Connect the digital TR sensor electrical connector. 6. Move the rubber boot back over the connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1272 7. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. 8. Verify that the selector lever cable is adjusted correctly. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 1277 View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 1278 View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1281 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1282 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1283 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1284 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1285 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1286 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1287 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1288 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1289 Transmission Speed Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1290 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1291 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1292 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1293 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1294 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1295 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1296 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1297 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1298 Transmission Speed Sensor: Connector Views C193 C143 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1299 C164 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 1302 6. Remove the selector lever cable and bracket. 7. Disconnect the turbine shaft speed (TSS) sensor electrical connector. 8. Remove the TSS sensor. 1 Remove the TSS sensor screw. 2 Remove the TSS sensor from the transmission. ^ Inspect the TSS sensor O-ring for damage. If damaged, install a new O-ring. Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the TSS sensor into the transmission. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 1303 2 Tighten the TSS sensor screw. ^ Tighten to 14 Nm (10 ft. lbs.) 2. Connect the TSS sensor electrical connector. 3. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable and bracket. ^ Tighten to 40 Nm (30 ft. lbs.) 4. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 1304 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Install the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 ft. lbs.) 7. Install the front driveshaft to the front differential. ^ Tighten to 18 Nm (13 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 1305 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 1306 6. Remove the selector lever cable and bracket. 7. Disconnect the heated oxygen sensor (HO2S) sensor connector from the transmission case. 8. Disconnect the output shaft speed (OSS) sensor electrical connector. 9. Remove the 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, install a new O-ring. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 1307 Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the OSS sensor into the transmission. 2 Tighten the OSS sensor screw. ^ Tighten to 14 Nm (10 ft. lbs.) 2. Connect the OSS sensor electrical connector. 3. Connect the HO2S connector to the transmission case. 4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 1308 cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable and bracket. ^ Tighten to 40 Nm (30 ft. lbs.) 5. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. 4WD vehicles 6. Install the front driveshaft in the vehicle. 7. Install the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 1309 8. Install the front driveshaft to the front differential. ^ Tighten to 18 Nm (13 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 1310 Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor Intermediate Shaft Speed Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 1311 6. Remove the selector lever cable and bracket. 7. Disconnect the intermediate shaft speed sensor electrical connector. 8. Remove the intermediate shaft speed sensor. 1 Remove the intermediate shaft speed sensor screw. 2 Remove the intermediate shaft speed sensor from the transmission. ^ Inspect the intermediate shaft speed sensor O-ring for damage. If damaged, install a new O-ring. Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the intermediate shaft speed sensor into the transmission. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 1312 2 Tighten the intermediate shaft speed sensor screw. ^ Tighten to 14 Nm (10 ft. lbs.) 2. Connect the intermediate shaft speed sensor electrical connector. 3. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable and bracket. ^ Tighten to 40 Nm (30 ft. lbs.) 4. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 1313 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Install the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 ft. lbs.) 7. Install the front driveshaft to the front differential. ^ Tighten to 18 Nm (13 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1318 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1319 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1320 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1321 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1322 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1323 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1324 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1325 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1326 Transmission Temperature Sensor/Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1327 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1328 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1329 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1330 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1331 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1332 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1333 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1334 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch View 151-21 (Driver Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 1340 View 151-22 (Passenger Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 1341 View 151-24 (Left Rear Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 1342 View 151-23 (Right Rear Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch Power Window Switch: Diagrams Master Window Adjust Switch C504A C504B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 1345 C701 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 1346 C604 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 1347 C801 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 1350 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 1351 Power Window Switch: Service and Repair WINDOW CONTROL SWITCH Removal and Installation 1. Remove the interior door handle cover. 2. Lift the window control switch bezel upward to release the clips. 3. Disconnect the window control switch electrical connectors from the window control switch. 4. Disconnect the window control switch from the window control switch bezel to remove. 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations View 151-2 (Engine Compartment - 4.0L, (2 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 1356 C138 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Multifunction Switch View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Multifunction Switch > Page 1361 View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Multifunction Switch C202 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Multifunction Switch > Page 1364 C2347 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 1367 Windshield Washer Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 1368 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 1369 Windshield Washer Switch: Service and Repair Steering Column Multifunction Switch Steering Column Multifunction Switch Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column can result. 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the 2 screws and the steering column opening cover. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 1370 3. Remove the 3 screws and the upper and lower steering column shroud. 4. Disconnect the multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the multi-function switch. 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1374 C202 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch, Wiper/Washer Portion Wiper Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch, Wiper/Washer Portion > Page 1377 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch, Wiper/Washer Portion > Page 1378 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 1379 Wiper Switch: Service and Repair Steering Column Multifunction Switch Steering Column Multifunction Switch Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column can result. 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the 2 screws and the steering column opening cover. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 1380 3. Remove the 3 screws and the upper and lower steering column shroud. 4. Disconnect the multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the multi-function switch. 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1386 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1387 Alignment: Specifications General Specifications General Specifications General Specifications (Part 1) General Specifications (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1388 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1389 Alignment: Specifications General Specifications General Specifications General Specifications (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1390 General Specifications (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1391 Alignment: Description and Operation Suspension System The front camber and caster are adjusted by loosening the upper control arm bolts which will allow the upper arm to be moved in the slotted frame holes. The LF caster can be adjusted by loosening the lower control arm rearward nut to allow the lower arm to be moved in the slotted frame hole. Front toe is adjusted by the use of the front wheel spindle tie rods. The rear camber is adjusted by replacing the upper arm inboard flag nut with a non-flag nut to allow the arm to be adjusted in the slotted frame holes. The rear toe is adjusted through the use of the rear toe link cam bolt. 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 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. Toe Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1392 Positive Toe (Toe In) 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. Ride Height Front Ride Height Measurement Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1393 Rear Ride Height Measurement Thrust Angle (Dogtracking) Thrust Angle (Dogtracking) Thrust angle (also known as dogtracking) is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can give the illusion of incorrect thrust angle. 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. 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. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1394 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 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. 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, such as wind or road camber. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front Alignment: Service and Repair Camber and Caster Adjustment - Front Camber and Caster Adjustment - Front 1. Using alignment equipment and the manufacturer's instructions, measure the front caster and camber. 2. Loosen the upper arm bolt(s) and adjust the caster and camber settings. Refer to the chart. ^ When making adjustments that require moving both the front and the rear of the upper arm, move both ends of the arm equally. 3. NOTE: Make sure that the weight of the vehicle is on the wheels and that the caster and camber settings are not disturbed while tightening the bolt(s). Tighten the upper arm bolt(s) to 150 Nm (111 ft. lbs.) 4. NOTE: A caster split adjustment can be made by loosening the LF lower arm rearward nut and adjusting the rear of the LF lower arm. Remove and discard the LF lower control arm rearward nut. 5. NOTE: Do not fully tighten the nut and bolt at this time. Install a new LF lower control arm rearward nut. 6. Position the LF lower control arm until the caster split is within specification. 7. NOTE: Make sure that the weight of the vehicle is on the wheels and that the caster settings are not disturbed while tightening the nut. Tighten the LF lower control arm rearward nut to 200 Nm (148 ft. lbs.) 8. Recheck the camber and caster, adjust as necessary. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front > Page 1397 9. Check and, if necessary, adjust the front toe. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front > Page 1398 Alignment: Service and Repair Toe Adjustment - Front Toe Adjustment - Front 1. Using alignment equipment and the manufacturer's instructions, measure the front toe. 2. Start the engine and center the steering wheel. 3. Turn the engine OFF and, using a suitable holding device, lock the steering wheel in the straight ahead position. 4. NOTE: Do not allow the steering gear bellows to twist when the front wheel inner tie rod is rotated. Remove the clamps. 5. Loosen the tie-rod jam nuts.Rotate the front wheel inner tie rods until the toe setting is within specification. 6. CAUTION: Make sure to hold the tie-rod end stationary while tightening the nut or damage to the steering gear bellows can occur. NOTE: Make sure that the toe settings are not disturbed while tightening the nuts. Tighten the tie-rod jam nuts to 70 Nm (52 ft. lbs.) 7. Install the clamps. 8. Recheck the toe settings and adjust if necessary. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front > Page 1399 Alignment: Service and Repair Toe Adjustment - Rear Toe Adjustment - Rear 1. Using alignment equipment and the manufacturer's instructions, measure the rear toe. 2. Start the engine and center the steering wheel. 3. Turn the engine OFF and, using a suitable holding device, lock the steering wheel in the straight ahead position. 4. Loosen the rear toe link inboard nut. 5. Rotate the rear toe link cam bolt until the toe setting is within specification. 6. NOTE: Make sure the toe settings are not disturbed while tightening the nut. While holding the adjustment cam bolt, tighten the toe link inboard nut. ^ Tighten to 275 Nm (202 ft. lbs.) 7. Recheck the toe settings and adjust if necessary. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front > Page 1400 Alignment: Service and Repair Camber Adjustment - Rear Camber Adjustment - Rear 1. Index-mark the upper arm inboard bolt to the frame. 2. NOTE: The upper arm inboard flag nut must be removed and replaced with a non-flag nut to allow for the adjustment of the arm in the frame slot. Remove and discard the upper arm inboard bolt and flagnut. ^ Install a new non-flagnut.Using alignment equipment and the manufacturer's instructions, measure the rear camber. 3. NOTE: The weight of the vehicle must be off of the wheels in order to adjust the rear camber. NOTE: For camber adjustment, 1 mm (0.03 inch) of movement equals 0.24 degrees of camber. NOTE: To decrease the camber, move the upper arm inward. To increase the camber, move the upper arm outward. Position the upper arm until the camber setting is within specification. 4. NOTE: Make sure that the camber settings are not disturbed while tightening the nut. Tighten the upper arm inboard nut to 250 Nm (185 ft. lbs.) 5. Recheck the camber settings and adjust as necessary. 6. Check and, if necessary, adjust the rear toe. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Item....................................................................................................................................................... ..............................................................Specification Fuel Pressure Key on, engine off................................................................................................................................. .............................................207-276 kPa (30-40 psi) Engine running................................................. ..................................................................................................................................207-276 kPa (30-40 psi) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Hot Idle Speed ..................................................................................................................................... ............................................................ 750-820 RPM Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair AIR CLEANER ELEMENT Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1412 Exploded View Removal and Installation NOTE: Do not disconnect the mass air flow (MAF) sensor electrical connector. Vehicles equipped with a 4.0L (SOHC) engine 1. Detach the wiring harness retainer from the air cleaner outlet pipe. Vehicles equipped with a 4.6L (3V) engine Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1413 2. Detach the wiring harness retainer from the coolant expansion tank. All vehicles 3. Loosen the clamp and disconnect the air cleaner outlet pipe from the air cleaner. 4. Unclip and remove the air cleaner cover. 5. Remove the air cleaner element. 6. NOTE: Clean the inside of the air cleaner tray. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE 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. - 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, which can cause a fire hazard. Failure to follow these instructions may result in personal injury. 1. NOTE: The front passenger door frame scuff plate is retained only by internal metal clips. Remove the front passenger door frame scuff plate. 2. NOTE: - The front passenger door side interior kick panel is retained only by internal metal clips. - It may be necessary to reposition the lower end of the door jam weather stripping to remove the front passenger door side interior kick panel. Remove the front passenger side interior kick panel. 3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Start the engine and allow it to idle until it stalls. 5. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail pressure has been released. 6. Turn the ignition switch to the OFF position. 7. When the fuel system service is complete, reconnect the IFS switch electrical connector. 8. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 9. Start the vehicle and check the fuel system for leaks. 10. Install the front passenger side interior kick panel. 11. Install the front passenger door frame scuff plate. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Item....................................................................................................................................................... ..............................................................Specification Firing order........................................................................................................................................... ..................................................................1-4-2-5-3-6 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > System Information > Specifications Ignition Timing: Specifications Item....................................................................................................................................................... ..............................................................Specification Base ignition timing.............................................................................................................................. ..............................10 degrees BTDC Non-adjustable Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair Ignition Cable: Service and Repair SPARK PLUG WIRES Exploded View Special Tool(s) Special Tool(s) Removal and Installation 1. CAUTION: It is important to twist the spark plug wire boot while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Page 1427 Squeeze the locking tabs and twist while pulling upward to disconnect the 6 spark plug wires from the ignition coil. 2. Detach the spark plug wires from the spark plug wire retainers. 3. CAUTION: It is important to twist the spark plug wire boot while pulling upward to avoid damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct spark plug. With a twisting motion, use the special tool to pull the spark plug wires from the spark plugs. 4. NOTE: Apply silicone dielectric compound to the inside of the spark plug wire boots. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > General Specifications Spark Plug: Specifications General Specifications Item....................................................................................................................................................... ..............................................................Specification Spark plug gap..................................................................................................................................... ....................................1.32-1.42 mm (0.052-0.056 in) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > General Specifications > Page 1432 Torque Specifications Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1433 Spark Plug: Application and ID SPARK PLUG TYPE LH ........................................................................................................................................................ .......................................................... AGSF24PM RH ....................................................................................................................................................... ........................................................ AGSF24PGM Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1434 Spark Plug: Testing and Inspection Spark Plug Inspection 1. Inspect the spark plug for a bridged gap. ^ Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or carbon fouling. ^ Clean the spark plug. 2. Check for oil fouling. ^ Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil entering the combustion chamber through worn rings and pistons, excessive valve-to-guide clearance or worn or loose bearings. ^ Correct the oil leak concern. ^ Install a new spark plug. 3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips, exposed shell surfaces and electrodes, caused by a spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive idling. ^ Clean the spark plug. 4. Inspect for normal burning. ^ Check for light tan or gray deposits on the firing tip. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1435 5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator. Metallic deposits on the insulator indicate engine damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized installation of a heli-coil insert in place of the spark plug threads. ^ Install a new spark plug. 6. Inspect for overheating, identified by white or light gray spots and with bluish-burnt appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing. ^ Install a new spark plug. 7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. ^ Clean the spark plug. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1436 Spark Plug: Service and Repair SPARK PLUGS Exploded View Special Tool(s) Removal and Installation Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1437 1. CAUTION: It is important to twist the spark plug wire boot while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct spark plug. With a twisting motion, use the special tool to pull the spark plug wire from the spark plug. 2. NOTE: Use compressed air to remove any foreign material from the spark plug wells before removing the spark plugs Remove the spark plugs. To install, tighten to 17 Nm (13 lb-ft). 3. Use a suitable spark plug gap tool to check and adjust the spark plug gap. 4. NOTE: Apply silicone dielectric compound to the inside of the spark plug wire boots. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 at least 75% of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Compression Pressure Limit Chart Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1441 Compression Check: Testing and Inspection Compression Test - Compression Gauge Check 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 5 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 at least 75% of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Compression Pressure Limit Chart If one or more cylinders read low, squirt approximately one tablespoon of engine oil 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. 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If 2 adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1442 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 at least 75% of the highest reading. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 09-7-7 > Apr > 09 > Engine - Squeal/Chirp On Cold Start Up Drive Belt: Customer Interest Engine - Squeal/Chirp On Cold Start Up TSB 09-7-7 04/20/09 4.0L ENGINE BELT SQUEAL OR CHIRP NOISE ON COLD STARTUP FORD: 2009 Mustang 2007-2008 Explorer Sport Trac, Explorer MERCURY: 2007-2008 Mountaineer ISSUE Some 2007-2008 Explorer, Explorer Sport Trac, Mountaineer and 2009 Mustang vehicles equipped with a 4.0L engine may exhibit a belt squeal or belt chirp from the front end accessory drive (FEAD) belt near the power steering pulley area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE UNDER NO CIRCUMSTANCES SHOULD THE ACCESSORY DRIVE BELT, TENSIONER OR PULLEYS HAVE ANY FLUIDS OR BELT DRESSING APPLIED TO THEM AS DAMAGE TO THE BELT MATERIAL AND TENSIONER DAMPING MECHANISM MAY OCCUR. 1. Visually inspect all related FEAD components for damage and or abnormal wear. Reference the online Work Shop Manual (WSM), Section 303-05.If no concerns found, proceed to Step 2. 2. Inspect for FEAD belt clearance on the idler pulley. A properly aligned belt will have an approximate 3/32" (2 mm) space behind the belt on the idler pulley. (Figure 1) a. If there is not an approximate 3/32" (2 mm) gap, proceed with Step 3. b. If there is an approximate 3/32" (2 mm) gap, proceed with Step 5. 3. Verify the generator bracket and idler pulley are properly seated and torqued to specification. Reference the online (WSM), Section 303-05. a. If they are not properly seated or torqued to specification, after correcting them, remeasure the gap per Step 2. (1) If the gap is still not 3/32" (2 mm), proceed to Step 4. (2) If there is an approximate 3/32" (2 mm) gap, proceed to Step 5. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 09-7-7 > Apr > 09 > Engine - Squeal/Chirp On Cold Start Up > Page 1451 b. If no concerns are found with fit or torque, proceed to Step 4. 4. Replace the generator bracket with updated bracket. Reference online (WSM), Section 303-01. Proceed to Step 5. 5. Replace the accessory drive belt with the updated belt part number. Reference online (WSM), Section 303-05. Parts Block 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 090707A 2009 Mustang, 2007-2008 0.3 Hr. Explorer, Explorer Sport Trac, Mountaineer 4.0L: Inspect And Replace FEAD Belt Includes Time For Measurements (Do Not Use With 10346A, 6209A, 8678A, 8620F) 090707B 2009 Mustang, 2007-2008 0.8 Hr. Explorer, Explorer Sport Trac, Mountaineer 4.0L: Inspect And Replace Alternator Bracket And FEAD Belt Includes Time For Measurements (Do Not Use With 10346A, 6209A, 8678A, 8620F) DEALER CODING CONDITION BASIC PART NO. CODE 10A313 07 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 09-7-7 > Apr > 09 > Engine - Squeal/Chirp On Cold Start Up Drive Belt: All Technical Service Bulletins Engine - Squeal/Chirp On Cold Start Up TSB 09-7-7 04/20/09 4.0L ENGINE BELT SQUEAL OR CHIRP NOISE ON COLD STARTUP FORD: 2009 Mustang 2007-2008 Explorer Sport Trac, Explorer MERCURY: 2007-2008 Mountaineer ISSUE Some 2007-2008 Explorer, Explorer Sport Trac, Mountaineer and 2009 Mustang vehicles equipped with a 4.0L engine may exhibit a belt squeal or belt chirp from the front end accessory drive (FEAD) belt near the power steering pulley area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE UNDER NO CIRCUMSTANCES SHOULD THE ACCESSORY DRIVE BELT, TENSIONER OR PULLEYS HAVE ANY FLUIDS OR BELT DRESSING APPLIED TO THEM AS DAMAGE TO THE BELT MATERIAL AND TENSIONER DAMPING MECHANISM MAY OCCUR. 1. Visually inspect all related FEAD components for damage and or abnormal wear. Reference the online Work Shop Manual (WSM), Section 303-05.If no concerns found, proceed to Step 2. 2. Inspect for FEAD belt clearance on the idler pulley. A properly aligned belt will have an approximate 3/32" (2 mm) space behind the belt on the idler pulley. (Figure 1) a. If there is not an approximate 3/32" (2 mm) gap, proceed with Step 3. b. If there is an approximate 3/32" (2 mm) gap, proceed with Step 5. 3. Verify the generator bracket and idler pulley are properly seated and torqued to specification. Reference the online (WSM), Section 303-05. a. If they are not properly seated or torqued to specification, after correcting them, remeasure the gap per Step 2. (1) If the gap is still not 3/32" (2 mm), proceed to Step 4. (2) If there is an approximate 3/32" (2 mm) gap, proceed to Step 5. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 09-7-7 > Apr > 09 > Engine - Squeal/Chirp On Cold Start Up > Page 1457 b. If no concerns are found with fit or torque, proceed to Step 4. 4. Replace the generator bracket with updated bracket. Reference online (WSM), Section 303-01. Proceed to Step 5. 5. Replace the accessory drive belt with the updated belt part number. Reference online (WSM), Section 303-05. Parts Block 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 090707A 2009 Mustang, 2007-2008 0.3 Hr. Explorer, Explorer Sport Trac, Mountaineer 4.0L: Inspect And Replace FEAD Belt Includes Time For Measurements (Do Not Use With 10346A, 6209A, 8678A, 8620F) 090707B 2009 Mustang, 2007-2008 0.8 Hr. Explorer, Explorer Sport Trac, Mountaineer 4.0L: Inspect And Replace Alternator Bracket And FEAD Belt Includes Time For Measurements (Do Not Use With 10346A, 6209A, 8678A, 8620F) DEALER CODING CONDITION BASIC PART NO. CODE 10A313 07 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1458 Drive Belt: Diagrams Front End Accessory Drive (FEAD) - Exploded View, 4.0L SOHC Front End Accessory Drive (FEAD) - Exploded View, 4.0L SOHC Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Drive Belt: Initial Inspection and Diagnostic Overview Accessory Drive Inspection and Verification CAUTION: Under no circumstances should the accessory drive belt, tensioner or pulleys be lubricated as potential damage to the belt material and tensioner damping mechanism will occur. Do not apply any fluids or belt dressing to the accessory drive belt or pulleys. 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical damage. Visual Inspection Chart Visual Inspection Chart 3. Eliminate all other non-belt related noises that could cause belt misdiagnosis, such as A/C compressor engagement chirp, power steering cavitations at low temperatures, variable camshaft timing (VCT) tick or generator whine. 4. If a concern is found, correct the condition before proceeding to the next step. V-Ribbed Serpentine Drive Belt With Cracks Across Ribs V-Ribbed Serpentine Drive Belt With Cracks Across Ribs 5. NOTE: Up to 15 cracks in a rib over a distance of 100 mm (4.0 inch) can be considered acceptable. If damage exceeds the acceptable limit or any chunks are found to be missing from the ribs, a new belt must be installed. Check the belt for cracks. Up to 15 cracks in a rib over a distance of 100 mm (4.0 inch) can be considered acceptable. If cracks exceed this standard, install a new belt. 6. The condition of the V-ribbed drive belt should be compared against the illustration and appropriate action taken. 1 Small scattered deposits of rubber material. This is not a concern, therefore, installation of a new belt is not required. 2 Longer deposit areas building up to 50% of the rib height. This is not considered a concern but it can result in excessive noise. If noise is apparent, install a new belt. 3 Heavy deposits building up along the grooves resulting in a possible noise and belt stability concern. If heavy deposits are apparent, install a new belt. V-Ribbed Serpentine Belt With Piling NOTE: Piling is an excessive buildup in the V-grooves of the belt. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1461 V-Ribbed Serpentine Belt With Piling 7. There should be no chunks missing from the belt ribs. If the belt shows any evidence of this, install a new accessory drive belt. V-Ribbed Serpentine Belt With Chunks of Rib Missing V-Ribbed Serpentine Belt With Chunks Of Rib Missing 8. If the concern is not visually evident, verify the symptom and GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1462 Drive Belt: Symptom Related Diagnostic Procedures Symptom Chart (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1463 Symptom Chart (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1464 Drive Belt: Component Tests and General Diagnostics Drive Belt - Noise/Flutter Drive Belt - Noise/Flutter Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a damaged or incorrectly aligned grooved pulley. To correct, determine the area where the noise comes from. Check each of the pulleys in that area with a straightedge to the crankshaft pulley. Look for accessory pulleys out of position in the fore/aft direction or at an angle to the straightedge. CAUTION: Do not apply any fluids or belt dressing to the accessory drive belt or pulleys. Drive belt squeal may be an intermittent or constant noise that occurs when the drive belt slips on an accessory pulley under certain conditions. A short intermittent squeal may occur during engine start-up and shut down or during very rapid engine acceleration and decelerations, such as: ^ wide open throttle 1-2 and 2-3 shifts or 2-3 and 3-4 back out shifts on automatic transmissions. ^ wide open throttle 1-2 and 2-3 shifts and any combination of rapid downshifting on manual transmissions. These special short-term transient events are expected, and are due to the higher system inertias required to meet the electrical and cooling demands on today's vehicle systems. Constant or reoccurring drive belt squeal can occur: ^ if the A/C discharge pressure goes above specifications: ^ the A/C system is overcharged. ^ the A/C condenser core airflow is blocked. ^ if the A/C off equalized pressure (the common discharged and suction pressure that occurs after several minutes) exceeds specifications. ^ if any of the accessories are damaged or have a worn or damaged bearing. All accessories should be rotatable by hand in the unloaded condition. If not, inspect the accessory. ^ if there is evidence of fluid contamination on the accessory drive belt. When the drive belt has been exposed to fluid contamination during vehicle operation, such as leaks from the power steering system, A/C system or cooling system, clean all pulleys with soap and water, rinse with clean water and install a new accessory drive belt. If the drive belt has been exposed to fluids in a localized area during routine vehicle service, such as replacement of hoses or fluids, the drive belt and pulleys should be washed with soap and water immediately (prior to starting the engine), and rinsed with clean water. ^ if the accessory drive belt is too long. A drive belt that is too long will allow the accessory drive belt tensioner arm to go all the way to the arm travel stop under certain load conditions, which will release tension to the drive belt. If the accessory drive belt tensioner indicator is outside the normal installation wear range window, install a new accessory drive belt. ^ NOTE: The accessory drive belt tensioner arm should rotate freely without binding. Install a new accessory drive belt tensioner if the drive belt tensioner is worn or damaged. Drive Belt - Incorrect Installation Drive Belt - Incorrect Installation CAUTION: Incorrect accessory drive belt installation will cause excessive drive belt wear and can cause the drive belt to come off the pulleys. Non-standard accessory drive belts can track differently or incorrectly. If an accessory drive belt tracks incorrectly, install a new accessory drive belt to avoid performance failure or loss of the drive belt. Incorrect Installation Incorrect Installation Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1465 Correct Installation Correct Installation With the engine running, check accessory drive belt tracking on all pulleys. If the edge of the accessory drive belt rides beyond the edge of the pulleys, noise and premature wear will occur. Make sure the accessory drive belt rides correctly on the pulley. If an accessory drive belt tracking condition exists, proceed with the following: ^ Visually check the accessory drive belt tensioner for damage, especially the mounting pad surface. If the accessory drive belt tensioner is not installed correctly, the mounting surface pad will be out of position. This will result in chirp and squeal noises. ^ With the engine running, visually observe the grooves in the pulleys (not the pulley flanges or the pulley forward faces) for excessive wobble. Install new components as necessary. ^ Check all accessories, mounting brackets and the accessory drive belt tensioner for any interference that would prevent the component from mounting correctly. Correct any interference condition and recheck the accessory drive belt tracking. ^ Tighten all accessories, mounting brackets and accessory drive belt tensioner retaining hardware to specification. Recheck the accessory drive belt tracking. Belt Tensioner - Mechanical Belt Tensioner - Mechanical The only mechanical check that needs to be made is a check for tensioner stick, grab or bind. 1. With the engine off, check routing of the accessory drive belt. Refer to the illustrations under Description and Operation. 2. NOTE: The accessory drive belt tensioner spring is very strong and requires substantial force to release. Using a suitable, commercially available serpentine belt tensioner release tool, release the tension on the belt and detach the accessory drive belt in the area of the tensioner. 3. Using a suitable, commercially available serpentine belt tensioner release tool, move the tensioner from its relaxed position, through its full stroke and back to the relaxed position to make sure there is no stick, grab or bind, and to make sure that there is tension on the tensioner spring. 4. Rotate the tensioner pulley by hand and check for a binding, contaminated or seized condition. Install a new accessory drive belt tensioner if necessary. 5. Inspect the area surrounding the accessory drive belt tensioner for oil leaks or contamination and repair any leaks. Install a new accessory drive belt tensioner as necessary. 6. If the accessory drive belt tensioner meets the above criteria, proceed to testing the tensioner dynamically. If the accessory drive belt tensioner does not meet the above criteria, install a new tensioner. Belt Tensioner - Dynamics Belt Tensioner - Dynamics The accessory drive belt tensioner can be checked dynamically as follows: 1. With the engine running, observe the accessory drive belt tensioner movement. The accessory drive tensioner should move (respond) when the air conditioning clutch cycles (if equipped), or when the engine is accelerated rapidly. If the accessory drive belt tensioner movement is excessive without air conditioning clutch cycling or engine acceleration, check belt rideout. Excessive belt rideout (uneven depth of grooves in the belt) can cause excessive accessory drive belt tensioner movement. Check rideout condition by installing a new belt. If excessive accessory drive belt tensioner movement still exists, install a new accessory drive belt tensioner. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 1466 Drive Belt: Service and Repair Accessory Drive Belt - 4.0L SOHC Removal and Installation 1. Rotate the accessory drive belt tensioner counterclockwise and remove the drive belt. 2. To install, reverse the removal procedure. ^ For correct belt routing, refer to Accessory Drive, Component Locations - 4.0L SOHC. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair AIR CLEANER ELEMENT Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1472 Exploded View Removal and Installation NOTE: Do not disconnect the mass air flow (MAF) sensor electrical connector. Vehicles equipped with a 4.0L (SOHC) engine 1. Detach the wiring harness retainer from the air cleaner outlet pipe. Vehicles equipped with a 4.6L (3V) engine Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1473 2. Detach the wiring harness retainer from the coolant expansion tank. All vehicles 3. Loosen the clamp and disconnect the air cleaner outlet pipe from the air cleaner. 4. Unclip and remove the air cleaner cover. 5. Remove the air cleaner element. 6. NOTE: Clean the inside of the air cleaner tray. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair The air distribution system of this vehicle cannot be equipped with a cabin air filter. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service and Repair Evaporative Canister Filter: Service and Repair DUST SEPARATOR Removal and Installation 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 can 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. NOTE: Use only water-based lubricants on the vapor hoses. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Disconnect the fuel vapor hose from the dust separator. 4. Disconnect the fuel filler pipe vapor hose from the dust separator. 5. Remove the bolt and the dust separator. - To install, tighten to 9 Nm (80 lb-in). 6. To install, reverse the removal procedure. - Lubricate the vapor hoses with a water-based lubricant to ease installation. 7. Leak test the evaporative emission system. See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Evaporative Emission System Leak Test 8. Carry out the evaporative emission repair drive cycle. See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Evaporative Emission Repair Verification Drive Cycle Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter Fluid Filter - A/T: Service and Repair Fluid Pan, Gasket and Filter Fluid Pan, Gasket and Filter Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Place a drain pan under the transmission fluid pan. 3. Remove the drain plug and drain the fluid. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the gasket should be reused. Remove the 16 transmission fluid pan screws, fluid pan and gasket. 5. Remove and discard the transmission fluid filter. 6. Clean and inspect the transmission fluid pan and magnet. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 1484 Installation 1. CAUTION: Damage may occur to fluid filter seals if they are not lubricated with clean automatic transmission fluid. NOTE: Make sure that the fluid filter seals are correctly seated on the filter. Lubricate the seals and install the transmission fluid filter. ^ Tighten to 10 Nm (89 inch lbs.) 2. Install the fluid pan magnet in the transmission fluid pan. 3. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the gasket should be reused. Install the fluid pan gasket on the pan. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 1485 4. Install the transmission fluid pan and gasket and loosely install the screws. 5. Tighten the screws in a crisscross sequence. ^ Tighten to 11 Nm (8 ft. lbs.) 6. Install the fluid drain plug. ^ Tighten to 26 Nm (19 ft. lbs.) 7. Partially fill the transmission. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 1486 Fluid Filter - A/T: Service and Repair Transmission Filter - In Line Transmission Filter - In Line Special Tool(s) Material NOTE: Use these guidelines for installing the transmission fluid in-line filter: ^ If the transmission was overhauled and the vehicle was equipped with an in-line fluid filter, install a new in-line fluid filter. ^ If the transmission was overhauled and the vehicle was not equipped with an in-line fluid filter, install a new in-line fluid filter kit. ^ If the transmission is being installed for a non-internal repair, do not install an in-line filter or filter kit. ^ If installing a Ford-authorized remanufactured transmission, install the in-line transmission fluid filter that is supplied. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the secondary latch from the fluid cooler connector. 3. Using the special tool, disconnect the fluid cooler connector. 4. Remove the section of the steel tube at the second flare. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 1487 ^ Clean and deburr the cut end of the steel tube. 5. NOTE: Be sure the cooler tube is fully seated in the body of the fitting before final tightening of the ferrule nut. Install the tubing ferrule hose assembly connector onto the end of the steel fluid cooler tube. Finger-tighten the ferrule nut, then tighten the nut an additional 1-1/2 turns to seat the ferrule in the connector. 6. Remove the section of the rubber hose as illustrated. 7. CAUTION: The filter has a bypass valve in it. The red arrow on the filter indicates the direction of fluid flow through the filter. The filter must be installed in the fluid cooler return line with the red arrow on the filter pointing away from the transmission fluid cooler and toward the transmission (the return line has fluid coming out of the cooler going to the transmission). If the fluid filter is not installed correctly, it will cause internal transmission damage. CAUTION: Do not install any rubber hoses or steel tubing with a bend entering the filter greater than 60°. Install the one end of the filter into the rubber hose with a clamp. ^ Tighten the hose clamp. 8. Using a suitable length of hose, install the other end of the filter into the tubing ferrule hose assembly with 2 clamps. ^ Tighten the hose clamps. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 1488 9. Clean a section of the transmission fluid pan, then install the sticker. 10. Fill the transmission with clean automatic transmission fluid. ^ Verify for correct operation. ^ Check the filter for leaks. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE 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. - 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, which can cause a fire hazard. Failure to follow these instructions may result in personal injury. 1. NOTE: The front passenger door frame scuff plate is retained only by internal metal clips. Remove the front passenger door frame scuff plate. 2. NOTE: - The front passenger door side interior kick panel is retained only by internal metal clips. - It may be necessary to reposition the lower end of the door jam weather stripping to remove the front passenger door side interior kick panel. Remove the front passenger side interior kick panel. 3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Start the engine and allow it to idle until it stalls. 5. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail pressure has been released. 6. Turn the ignition switch to the OFF position. 7. When the fuel system service is complete, reconnect the IFS switch electrical connector. 8. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 9. Start the vehicle and check the fuel system for leaks. 10. Install the front passenger side interior kick panel. 11. Install the front passenger door frame scuff plate. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair Coolant Line/Hose: Service and Repair Coolant Crossover Manifold Assembly Coolant Crossover Manifold Assembly (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Page 1497 Coolant Crossover Manifold Assembly (Part 2) Removal and Installation 1. Disconnect the battery ground cable. 2. Drain the engine cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding. 3. Remove the intake manifold. 4. Rotate the accessory drive belt tensioner clockwise and detach the belt from the generator pulley. 5. Disconnect the electrical connector. 6. Loosen the generator nuts. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Page 1498 ^ To install, tighten to 25 Nm (18 ft. lbs.). 7. Remove the generator bracket-to-coolant crossover bolts, and position the generator, bracket and wiring harness aside as an assembly. ^ To install, tighten to 10 Nm (89 inch lbs.). 8. Disconnect the PCV heater hose from the coolant crossover manifold assembly. 9. Disconnect the heater hose from the coolant crossover manifold assembly. 10. Disconnect the upper radiator hose from the coolant crossover manifold assembly. 11. Remove the bolts, the coolant crossover manifold assembly and the gaskets. Discard the gaskets. ^ To install, tighten to 10 Nm (89 inch lbs.). 12. To install, reverse the removal procedure. ^ Install new gaskets. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 (V6-4.0L VIN K (2007)) 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 1507 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 (V6-4.0L VIN K (2007)) 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 1508 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 (V6-4.0L VIN K (2007)) 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 (V6-4.0L VIN K (2007)) 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 1514 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 (V6-4.0L VIN K (2007)) 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 1515 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary Heater Outlet and Inlet Line - Front Heater Hose: Service and Repair Auxiliary Heater Outlet and Inlet Line - Front AUXILIARY HEATER OUTLET AND INLET LINE - FRONT Removal and Installation 1. Remove the RH running board. 2. Drain the engine coolant. 3. Remove the RH rear wheel. 4. Release the front auxiliary heater line front clamps and disconnect the heater hoses. 5. Release the front auxiliary heater line rear clamps and disconnect the heater hoses. 6. Remove the 3 auxiliary line bracket nuts. - To install, tighten to 6 Nm (53 lb-in). 7. Remove the 3 auxiliary line bracket bolts. - To install, tighten to 6 Nm (53 lb-in). 8. Remove the 6 auxiliary line brackets. 9. Remove the front auxiliary heater outlet and inlet lines. 10. To install, reverse the removal procedure. 11. Fill the engine cooling system, Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary Heater Outlet and Inlet Line - Front > Page 1518 Heater Hose: Service and Repair Auxiliary Heater Outlet and Inlet Line - Rear AUXILIARY HEATER OUTLET AND INLET LINE - REAR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine coolant. 3. Remove the spare tire. 4. Remove the 4 spare tire carrier bolts and the 2 spare tire carrier shield pin-type retainers. 5. Remove the spare tire carrier. 6. Release the 2 rear auxiliary heater line front hose clamps and disconnect the hoses. 7. Release the 2 rear auxiliary heater line rear hose clamps and disconnect the hoses. 8. Remove the 2 auxiliary line bracket nuts. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary Heater Outlet and Inlet Line - Front > Page 1519 - To install, tighten to 8 Nm (71 lb-in). 9. Remove the 2 auxiliary line brackets. 10. Remove the rear auxiliary heater outlet line. 11. Remove the rear auxiliary heater inlet line. 12. To install, reverse the removal procedure. 13. Fill the engine cooling system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line Hose/Line HVAC: Service and Repair Compressor to Condenser Discharge Line COMPRESSOR TO CONDENSER DISCHARGE LINE Removal and Installation 1. Recover the refrigerant. 2. Remove the compressor-to-condenser discharge line bracket nut and detach the bracket. - To install, tighten to 7 Nm (62 lb-in). 3. Remove the compressor discharge fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (11 lb-ft). 4. Disconnect the A/C pressure transducer electrical connector. 5. Remove the condenser inlet fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). 6. Remove the compressor-to-condenser discharge line. 7. To install, reverse the removal procedure. - Install a new gasket seal and O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 1524 8. Evacuate, leak test and charge the refrigerant system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 1525 Hose/Line HVAC: Service and Repair Condenser to Evaporator Line CONDENSER TO EVAPORATOR LINE Removal and Installation NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the suction accumulator. All vehicles 1. Remove the air cleaner and air cleaner outlet tube. 2. Recover the refrigerant. 3. Remove the powertrain control module (PCM) and PCM bracket. 4. Disconnect the RH wheel speed sensor electrical connector and detach the wire harness from the condenser-to-evaporator line bracket. Vehicles equipped with 4.6L engine 5. Remove the suction accumulator-to-compressor line bracket nut. - To install, tighten to 7 Nm (62 lb-in). All vehicles 6. Disconnect the evaporator core orifice access fitting. - Discard the O-ring seal. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 1526 7. Remove the condenser-to-evaporator line bracket nut. - To install, tighten to 7 Nm (62 lb-in). 8. Remove the condenser outlet fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). 9. Disconnect the auxiliary evaporator inlet line fitting (if equipped). - Discard the O-ring seals. 10. Remove the front portion of the condenser-to-evaporator line. 11. Remove the A/C line bracket nut at the dash panel and detach the bracket. - To install, tighten to 6 Nm (53 lb-in). 12. Disconnect the evaporator inlet fitting. - Discard the O-ring seals. 13. Remove the rear portion of the condenser-to-evaporator line. 14. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 15. Evacuate, leak test and charge the refrigerant system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 1527 Hose/Line HVAC: Service and Repair Auxiliary Evaporator Outlet and Inlet Line - Front AUXILIARY EVAPORATOR OUTLET AND INLET LINE - FRONT Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 1528 Part 2 Removal and Installation NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the accumulator. 1. Recover the refrigerant. 2. Disconnect the front auxiliary evaporator inlet line front fitting. - Discard the O-ring seals. 3. Remove the RH running board. 4. Disconnect the front auxiliary evaporator outlet line front fitting. 5. Remove the RH rear wheel. 6. Remove the front auxiliary evaporator line fitting nuts and disconnect the fittings. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 7. Remove the 3 auxiliary line bracket nuts. - To install, tighten to 6 Nm (53 lb-in). 8. Remove the 3 auxiliary line bracket bolts. - To install, tighten to 6 Nm (53 lb-in). 9. Remove the 6 auxiliary line brackets. 10. Remove the front auxiliary evaporator outlet and inlet lines. 11. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 12. Evacuate, leak test and charge the refrigerant system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 1529 Hose/Line HVAC: Service and Repair Auxiliary Evaporator Outlet and Inlet Line - Rear AUXILIARY EVAPORATOR OUTLET AND INLET LINE - REAR Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 1530 Part 2 Removal and Installation NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the accumulator. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the spare tire. 4. Remove the 4 spare tire carrier bolts and the 2 spare tire carrier shield pin-type retainers. 5. Remove the spare tire carrier. 6. Remove the 2 rear auxiliary evaporator line front fitting nuts and disconnect the fittings. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 7. Remove the 2 rear auxiliary evaporator line rear fitting nuts and disconnect the fittings. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 8. Remove the auxiliary line bracket nut. - To install, tighten to 6 Nm (53 lb-in). 9. Remove the 2 auxiliary line brackets. 10. Remove the rear auxiliary evaporator outlet line. 11. Remove the rear auxiliary evaporator inlet line. - Discard the thermostatic expansion valve (TXV) filter. 12. To install, reverse the removal procedure. - Install new O-ring seals. - Install a new TXV filter. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 13. Evacuate, leak test and charge the refrigerant system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair Power Steering Line/Hose: Service and Repair Power Steering Pump to Steering Gear Pressure Line Special Tool(s) Material Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Page 1534 Removal CAUTION: While repairing the power steering system, care should be taken to prevent the entry of contaminants or premature failure of the power steering components can result. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the power steering pump pulley. 3. Remove the steering line clamp plate nut. 4. Rotate the steering line clamp plate and disconnect the fluid cooler return line from the steering gear. ^ Discard the O-ring seal. 5. Disconnect the pressure line from the steering gear. ^ Discard the O-ring seal. 6. Remove the pressure line bracket-to-engine nut (4.6L) or bolt (4.0L). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Page 1535 7. Remove the pressure line-to-crossmember retainer bracket bolt. 8. Disconnect the pressure line-to-pump fitting. ^ Remove and discard the Teflon(R) O-ring seal. 9. Remove the pressure line. Installation 1. NOTE: A new Teflon(R) O-ring seal must be installed. Using the special tool, install a new Teflon(R) O-ring seal on the pressure line fitting. 2. Position the pressure line and connect the pressure line-to-pump fitting. ^ Tighten to 65 Nm (48 ft. lbs.) 3. Install the pressure line bracket-to-engine nut (4.6L) or bolt (4.0L). ^ Tighten to 11 Nm (8 ft. lbs.) 4. NOTE: New O-rings must be installed whenever the power steering lines are disconnected. Install a new O-ring seal and position the pressure line to the steering gear. 5. Install the pressure line bracket-to-crossmember bolt. ^ Tighten to 12 Nm (9 ft. lbs.) 6. Install a new O-ring seal and position the power steering gear-to-fluid cooler return hose to the steering gear. Rotate the steering line clamp plate into position. 7. Install the steering line clamp plate nut. ^ Tighten to 25 Nm (18 ft. lbs.) 8. Install the power steering pump pulley. 9. Fill the power steering system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid Ford Part Number ................................................................................................................................ ................................................... PM-1 or PM-1-C Ford Specification ...................................................................................................................................................... ESA-M6C25-A or WSS-M6C62-A Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity: Without auxiliary climate control ............................................................................................................................................................ 12.2 qts (11.5L) With auxiliary climate control ............................................................................................................... .................................................. 13.9 qts (13.2L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1544 Coolant: Fluid Type Specifications Engine Coolant .............................................................................................................................................. Motorcraft Premium Gold Engine Coolant VC-7-A ................................................................................................................................................. ............................... US except CA, OR and NM VC-7-B ................................................................................................................................................. ................................................. CA, OR and NM Note: Add the coolant type originally equipped in your vehicle. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid 5R55S .................................................................................................................. ......................................................................................... 13.0 qts (12.3L) 6R60 ................................ .............................................................................................................................................................. ............... 12.2 qts (11.6L) Note: Indicates only approximate dry-fill capacity. Some applications may vary based on cooler size and if equipped with an in-tank cooler. The amount of transmission fluid and fluid level should be checked by a qualified technician Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1549 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type 5R55S .................................................................................................................................................. ............................................................. MERCON V 6R60 .................................................................. .............................................................................................................................................. MERCON SP Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Level Check Fluid - A/T: Service and Repair Transmission Fluid Level Check Transmission Fluid Level Check Special Tool(s) Material NOTE: Left side of case shown. Fluid Fill Reference NOTE: Left side of case shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Level Check > Page 1552 Fluid Fill Reference 1. Using the scan tool, monitor the transmission fluid temperature (TFT) using PID: TFT. 2. Start the vehicle. 3. NOTE: Engine idle speed is approximately 650 rpm. While proceeding with this procedure, run the engine until the transmission fluid temperature is between 27 - 49°C (80 - 120°F). 4. Move the range selector lever slowly through each gear, stopping in each position and allowing the transmission to engage. 5. Place the range selector lever in the PARK position. 6. With the engine running and the vehicle set as close to level as possible, position it on a hoist. For additional information, refer to Maintenance /Service and Repair. 7. Hold the larger drain plug with a wrench and remove the small (center) fluid level indicating plug. 8. Install the special tool into the pan. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Level Check > Page 1553 9. NOTE: Prior to filling the special tool with clean transmission fluid, make sure that the canister is clean. Fill the special tool with clean automatic transmission fluid. 10. Hang the special tool under the vehicle. Position it upright and close to the transmission. 11. Connect the special tools. ^ Connect the open end of the fluid hose from the Fluid Transporter/Evacuator/Injector to the Fluid Level and Fill Plug Adapter at the bottom of the transmission fluid pan. 12. Apply a maximum of 206.85 kPa (30 psi) to the open end of the vacuum/pressure hose from the special tool. Fluid will immediately start flowing out of the special tool into the transmission fluid pan. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Level Check > Page 1554 13. Add 0.5L (1 pt) of transmission fluid into the fluid pan. Stop the process by releasing the air pressure and removing the air nozzle from the end of the hose. 14. Inspect the fluid level in the special tool. If the fluid drains back into the canister, the transmission is full. If no fluid drains back, more fluid will need to be added. Repeat Steps 12 and 13. 15. Once the transmission is full, place a hand vacuum pump on the open end of the vacuum/pressure hose on the special tool and apply vacuum to the system. This will pull out any extra fluid trapped in the system and direct it into the container. 16. Allow the fluid to drain. Make sure that the fluid temperature is between 27 - 49°C (80 - 120°F). When the fluid comes out as a thin stream or drip, the fluid is at the correct level. 17. Reinstall the small (center) fluid level indicating plug using a 3/16-inch Allen key. ^ Tighten to 10 Nm (89 inch lbs.) 18. Check the operation of the transmission by moving the range selector lever slowly through each gear, stopping in each position and allowing the transmission to engage. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Level Check > Page 1555 Fluid - A/T: Service and Repair Transmission Fluid Drain and Refill - Automated Equipment Transmission Fluid Drain and Refill - Automated Equipment Special Tool(s) Material Draining CAUTION: Do not use water-based cleaners, mineral spirits, brake cleaner or solvents that may contain acetone, xylene or heptane to clean and/or flush the transmission assembly, transmission components and the torque converter or transmission damage will occur. Use only clean transmission fluid designated for the transmission/converter being serviced. CAUTION: Always refer to the instructions supplied with the flush and fill machine. 1. With the vehicle in PARK, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 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 line. This will help remove any foreign material trapped in the fluid coolers. 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. With the engine running, check and adjust the transmission fluid level and check for any leaks. If fluid is needed, add fluid in increments of 0.24L (0.5 pt) until the correct level is achieved. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Level Check > Page 1556 Fluid - A/T: Service and Repair Transmission Fluid Drain and Refill - Without Torque Converter Drain Plug Transmission Fluid Drain and Refill - Without Torque Converter Drain Plug Special Tool(s) Material Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Level Check > Page 1557 Fluid Fill Reference Draining 1. With the vehicle in PARK, position it on a hoist. Set the vehicle as close to level as possible. For additional information, refer to Maintenance /Service and Repair. 2. Remove the drain plug (large plug) and allow the fluid to drain. Refill 1. Install the fluid drain plug. ^ Tighten to 26 Nm (19 ft. lbs.) 2. Hold the larger drain plug with a wrench and remove the small (center) fluid level indicating plug. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Level Check > Page 1558 3. Install the special tool into the pan. 4. NOTE: Prior to filling the special tool with clean transmission fluid, make sure that the canister is clean. Fill the special tool with clean automatic transmission fluid. 5. Hang the special tool under the vehicle, upright and close to the transmission. 6. Connect the special tools. ^ Connect the open end of the fluid hose from the Fluid Transporter/Evacuator/Injector to the Fluid Level and Fill Plug Adapter at the bottom of the transmission fluid pan. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Level Check > Page 1559 7. Apply a maximum of 206.85 kPa (30 psi) to the open end of the vacuum/pressure hose from the special tool. Fluid will immediately start flowing out of the special tool into the transmission fluid pan. 8. Add 1.89L or 2.83L (2 qt or 3 qt) of transmission fluid into the fluid pan. Stop the process by releasing the air pressure and removing the air nozzle from the end of the hose. 9. NOTE: Engine idle speed is approximately 650 rpm. Using the scan tool, start and run the engine until the transmission fluid temperature is between 27°C - 49°C (80°F - 120°F). 10. Inspect the fluid level in the special tool. If the fluid drains back into the canister, the transmission is full. If no fluid drains back, more fluid will need to be added. Repeat Steps 9 and 10. 11. Once the transmission is full, place a hand vacuum pump on the open end of the vacuum/pressure hose on the special tool and apply vacuum to the system. This will pull out any extra fluid trapped in the system and direct it into the container. 12. Allow the fluid to drain. When the fluid comes out as a thin stream or drip, the fluid is at the correct level. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Level Check > Page 1560 13. Reinstall the small (center) fluid level indicating plug. ^ Tighten to 10 Nm (89 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Level Check > Page 1561 Fluid - A/T: Service and Repair Transmission Fluid Cooler - Backflushing and Cleaning Transmission Fluid Cooler - Backflushing and Cleaning Material CAUTION: Whenever a transmission has been disassembled to install new parts or a new or remanufactured transmission has been installed, a new transmission fluid cooler, either in-tank, auxiliary or oil to air (OTA), if equipped will need to be installed. Using a suitable torque converter/fluid cooler cleaner, clean and backflush the transmission fluid cooler tubes. CAUTION: Do not use water-based cleaners, mineral spirits, brake cleaner or solvents that may contain acetone, xylene or heptane to clean and/or flush the transmission assembly, transmission components and the torque converter or transmission damage will occur. Use only clean transmission fluid designated for the transmission/converter being serviced. When internal wear or damage has occurred in the transmission, metal particles, clutch plate material or band material may have been carried into the transmission fluid cooler. These contaminants are a major cause of recurring transmission concerns and must be removed from the system before the transmission is put back in use. 1. Conduct backflushing with a suitable torque converter/transmission fluid cooler cleaner. Test the equipment to make sure that a vigorous fluid flow is present before proceeding. Install a new system filter if flow is weak or contaminated. 2. Remove and discard the in-line transmission fluid filter, if equipped. 3. To aid in attaching the cleaner to the transmission steel cooler lines, connect 2 additional rubber hoses to the transmission end of the steel transmission cooler lines as described. ^ Connect the cleaner tank pressure line to the steel transmission cooler return line (longest line). ^ Connect a tank return hose to the steel transmission cooler pressure line (shorter line). Place the outlet end of this hose in the solvent tank reservoir. 4. Turn on the pump and allow the transmission fluid to circulate a minimum of 5 minutes (cycling switch on and off will help dislodge contaminants in the cooler system). 5. Switch off the pump and disconnect the pressure hose from the transmission cooler return line. 6. Use compressed air to blow out the cooler(s) and lines (blow air into the transmission cooler return line) until all the fluid is removed. 7. Remove the rubber return hose from the remaining steel cooler line. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity Refill ..................................................................................................................................................... ........................................................... 3.5 pts. (1.7L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1566 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Type ................................................................................................................................. SAE 75W-140 High Performance Synthetic Rear Axle Lubricant Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Page 1567 Fluid - Differential: Service and Repair Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear Differential Draining and Filling Special Tool(s) Material Fluid Check 1. NOTE: Before removing, clean the area around the filler plug. Remove the fill plug. Fluid Drain and Fill 1. Remove the drain plug. 2. Clean and install the drain plug. ^ Tighten to 34 Nm (25 ft. lbs.) 3. Fill the axle to the bottom of the fill plug hole. 4. Install the fill plug. ^ Tighten to 34 Nm (25 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1572 Engine Oil: Fluid Type Specifications Engine Oil U.S. ......................................................................................................................................... Motorcraft SAE 5W-30 Premium Synthetic Blend Motor Oil Canada .................................................................................................................................................... Motorcraft SAE 5W-30 Super Premium Motor Oil Note: Use of synthetic or synthetic blend motor oil is not mandatory. Engine oil need only have the API Certification mark and meet the requirements of Ford Specification WSS-M2C929-A. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 1577 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1578 Power Steering Fluid: Specifications Power steering fluid ............................................................................................................................. ................................... Motorcraft MERCON ATF Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1579 Power Steering Fluid: Testing and Inspection Power Steering Fluid Leak Test NOTE: This test should only be carried out if a leak in the system has not been detected during a thorough visual inspection. Refer to Inspection and Verification. See: Steering and Suspension/Steering/Testing and Inspection/Initial Inspection and Diagnostic Overview/Inspection and Verification 1. Check the power steering fluid level. If necessary, add the specified power steering fluid. 2. Remove the power steering pump reservoir cap and tightly install the evacuation cap to the power steering pump reservoir. 3. Install the hose from the fill adapter manifold tee to the evacuation cap on the power steering pump reservoir. 4. Install the vacuum pump to the evacuation cap. 5. Using the vacuum pump, apply 68 - 85 kPa (20 - 25 in-Hg) of vacuum to the power steering system. 6. Observe the vacuum gauge for 30 seconds. If the vacuum gauge reading drops more than 3 kPa (0.88 in-Hg) a leak is present. 7. Remove the vacuum pump. 8. CAUTION: Do not hold the steering wheel at the stops for more than 3-5 seconds. Damage to the power steering pump can occur. Start the engine. With the engine at idle, raise the power steering fluid temperature to 74 - 80°C (165 - 176°F) by rotating the steering wheel fully to the left and right several times. 9. Visually inspect the system for leaks. If a leak is evident, repair as necessary. If a leak is not evident, add the specified UV fluorescent tracer dye to the power steering fluid. Use 14.78 mL (1/2 oz) of dye solution for every 1.89 L (2 qt) of power steering fluid. 10. CAUTION: Do not hold the steering wheel at the stops for more than 3-5 seconds. Damage to the power steering pump can occur. Start the engine. With the engine at idle, raise the power steering fluid temperature to 74 - 80°C (165 - 176°F) by rotating the steering wheel fully to the left and right several times. 11. NOTE: On vehicles with rack and pinion steering gear, it may be necessary to remove the bellows boot clamp from the steering gear bellows boots to inspect for internal steering gear leaks. Using the special tool (UV lamp), inspect the system for traces of UV dye. Repair as necessary. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Item....................................................................................................................................................... ..............................................................Specification Refrigerant Capacity Capacity without auxiliary climate control............................................................................................. ......................................................0.88 kg (31 oz) Capacity with auxiliary climate control................... .....................................................................................................................................1.33 kg (47 oz) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1584 Refrigerant: Fluid Type Specifications Item....................................................................................................................................................... ..............................................................Specification Refrigerant Type R134a Refrigerant YN-19 .................................................................................................................... .................................................. WSH-M17B19-A Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1585 Refrigerant: Description and Operation REFRIGERANT SYSTEM DYE Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in refrigerant system leak diagnosis using a Rotunda-approved ultraviolet blacklight. It is not necessary to add additional dye to the refrigerant system before diagnosing leaks, even if a significant amount of refrigerant has been removed from the system. Replacement suction accumulators are shipped with a fluorescent dye "wafer" included in the desiccant bag which will dissolve after approximately 30 minutes of continued A/C operation. It is not necessary to add dye after flushing or filtering the refrigerant system because a new suction accumulator is installed as part of the flushing or filtering procedure. Additional refrigerant system dye should only be added if more than 50% of the refrigerant system lubricant capacity has been lost due to a fitting separation, hose rupture or other damage. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Item....................................................................................................................................................... ..............................................................Specification Refrigerant Oil Capacity Capacity without auxiliary climate control............................................................................................. ......................................................266 ml (9 fl oz) Capacity with auxiliary climate control................... ...................................................................................................................................473 ml (16 fl oz) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1590 Refrigerant Oil: Fluid Type Specifications Item....................................................................................................................................................... ..............................................................Specification Refrigerant Oil Type PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D ............................................................................................................. WSH-M1C231-B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > Customer Interest for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel Brake Bleeding: Customer Interest Brakes - Poor Brake Pedal Feel TSB 09-1-6 01/26/09 IMPROVED BRAKE PEDAL FEEL AND FIRMNESS - BUILT BEFORE 5/31/2008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-2-8 to update the part list and add a production fix date. ISSUE Some 2006-2008 Explorer, Mountaineer, and 2007-2008 Sport Trac vehicles built before 5/31/2008 may experience customer concerns with brake pedal feel or firmness. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Bleed the brake system using the anti-lock brake system (ABS) hydraulic control unit (HCU) bleeding procedure found in Workshop Manual (WSM), Section 206-00. a. If the brake bleeding procedure resolves the concern, do not continue with this TSB and return the vehicle to the customer. b. If the brake bleeding procedure does not resolve the customer concern, replace the brake pedal assembly. 2. Remove brake pedal assembly, Refer to WSM Section 206-06. 3. Install updated brake pedal assembly. Parts Block 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 090106A 2006-2008 0.7 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System (Do Not Use With 2000A) 090106B 2006-2008 1.8 Hrs. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System, Replace The Brake Pedal Assembly (Do Not Use With 2000A, Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > Customer Interest for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel > Page 1599 13480A, 9818A8) DEALER CODING CONDITION BASIC PART NO. CODE 2455 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > By Symptom for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel Brake Bleeding: By Symptom Brakes - Poor Brake Pedal Feel TSB 09-1-6 01/26/09 IMPROVED BRAKE PEDAL FEEL AND FIRMNESS - BUILT BEFORE 5/31/2008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-2-8 to update the part list and add a production fix date. ISSUE Some 2006-2008 Explorer, Mountaineer, and 2007-2008 Sport Trac vehicles built before 5/31/2008 may experience customer concerns with brake pedal feel or firmness. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Bleed the brake system using the anti-lock brake system (ABS) hydraulic control unit (HCU) bleeding procedure found in Workshop Manual (WSM), Section 206-00. a. If the brake bleeding procedure resolves the concern, do not continue with this TSB and return the vehicle to the customer. b. If the brake bleeding procedure does not resolve the customer concern, replace the brake pedal assembly. 2. Remove brake pedal assembly, Refer to WSM Section 206-06. 3. Install updated brake pedal assembly. Parts Block 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 090106A 2006-2008 0.7 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System (Do Not Use With 2000A) 090106B 2006-2008 1.8 Hrs. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System, Replace The Brake Pedal Assembly (Do Not Use With 2000A, Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > By Symptom for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel > Page 1605 13480A, 9818A8) DEALER CODING CONDITION BASIC PART NO. CODE 2455 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel Brake Bleeding: All Technical Service Bulletins Brakes - Poor Brake Pedal Feel TSB 09-1-6 01/26/09 IMPROVED BRAKE PEDAL FEEL AND FIRMNESS - BUILT BEFORE 5/31/2008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-2-8 to update the part list and add a production fix date. ISSUE Some 2006-2008 Explorer, Mountaineer, and 2007-2008 Sport Trac vehicles built before 5/31/2008 may experience customer concerns with brake pedal feel or firmness. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Bleed the brake system using the anti-lock brake system (ABS) hydraulic control unit (HCU) bleeding procedure found in Workshop Manual (WSM), Section 206-00. a. If the brake bleeding procedure resolves the concern, do not continue with this TSB and return the vehicle to the customer. b. If the brake bleeding procedure does not resolve the customer concern, replace the brake pedal assembly. 2. Remove brake pedal assembly, Refer to WSM Section 206-06. 3. Install updated brake pedal assembly. Parts Block 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 090106A 2006-2008 0.7 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System (Do Not Use With 2000A) 090106B 2006-2008 1.8 Hrs. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System, Replace The Brake Pedal Assembly (Do Not Use With 2000A, Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel > Page 1611 13480A, 9818A8) DEALER CODING CONDITION BASIC PART NO. CODE 2455 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake System Bleeding Brake Bleeding: Service and Repair Brake System Bleeding Brake System Bleeding Special Tools Material Master Cylinder Bleeding WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in personal injury. 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 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 new installation, air may get into the system and cause spongy brake pedal feel. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be gravity bled, manually bled or bled using pressure bleeding equipment. 1. NOTE: When a new brake master cylinder has been installed or the system has been emptied or partially emptied, it should be primed to prevent air from getting into the system. Disconnect the brake master cylinder tubes. 2. NOTE: Original equipment tubes are not intended to be used during this procedure. Install the 2 short brake tubes with the ends submerged in the brake master cylinder reservoir and fill the brake master cylinder reservoir with clean, specified brake fluid. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake System Bleeding > Page 1614 3. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes without air bubbles. 4. Remove the 2 short brake tubes and install the 2 master cylinder brake tubes. 5. Bleed each brake tube at the brake master cylinder as follows: 1 Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 2 Loosen the rear brake tube fitting until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the brake tube fitting. 3 Repeat this operation until clear, bubble-free fluid comes out. 4 Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front brake tube. 6. While the assistant maintains pressure on the brake pedal, tighten the master cylinder brake tubes. ^ Tighten to 18 Nm (13 ft. lbs.). Brake Caliper Bleeding NOTE: It is not necessary to bleed the entire brake system. It is possible to bleed only the opened part of the system. 1. Connect one end of a clear flexible hose to the bleeder screw. Submerge the other end in a container partially filled with clean, specified brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Open the caliper bleeder screw until brake fluid flows into the container. 4. When fluid stops flowing, close the bleeder screw. ^ Tighten to 10 Nm (89 inch lbs.) for the front brake bleeder screw and 22 Nm (16 ft. lbs.) for the rear brake bleeder screw. 5. Repeat the previous 3 steps until there are no air bubbles in the brake fluid. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake System Bleeding > Page 1615 Brake Bleeding: Service and Repair Anti-Lock Brake System (ABS) Hydraulic Control Unit (HCU) Bleeding Anti-Lock Brake System (ABS) Hydraulic Control Unit (HCU) Bleeding NOTE: This procedure is required only when a new HCU is installed. 1. Connect the scan tool and follow the ABS bleed instructions. 2. Use the caliper bleed procedure to bleed the system. Begin at the RH rear caliper. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Depowering and Repowering SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING Special Tool(s) Special Tool(s) Depowering 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. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the electrical connector on a safety canopy module. Doing so can result in safety canopy deployment. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a SRS component is being serviced, the SRS must be depowered. - 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. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box (SJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse 17 (10A) from the SJB. 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 switch to OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or installing any front or side air bag supplemental restraint system (SRS) components and before servicing, installing, 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 front impact severity sensors are located on the radiator support bracket above the lower front splash shield. The front door side impact sensors are located in the first row doors, behind the door trim panel. The C-pillar side impact sensors (if equipped) are located on the C-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). Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1620 remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install RCM fuse 17 (10A) to the SJB and close the cover. 4. 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. 5. Prove out the SRS as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch 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 6 seconds and then turn off. If an air bag SRS fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag indicator might not light 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 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 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous diagnostic trouble codes (DTCs) from the RCM and occupant classification sensor (OCS) module using a scan tool. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1621 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Deactivation and Reactivation SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION Special Tool(s) Special Tool(s) Deactivation 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. - Never probe the connectors on the safety canopy module. Doing so can result in safety canopy deployment, which can result in personal injury. - The safety belt pretensioner and adaptive load limiting retractor are pyrotechnic devices. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner/adaptive load limiting retractor. Never probe a pretensioner or adaptive load limiting retractor electrical connector. Doing so could result in pretensioner, adaptive load limiting retractor or air bag deployment and could result in personal injury. - 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a SRS component is being serviced, the SRS must be depowered. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1622 - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a SRS fault. - 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 smart junction box (SJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse 17 (10A) from the SJB. 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 front impact severity sensors are located on the radiator support bracket above the lower front splash shield. The front door side impact sensors are located in the first row doors, behind the door trim panel. The C-pillar side impact sensors (if equipped) are located on the C-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). Disconnect the battery ground cable and wait at least one minute. 7. Remove the 2 driver air bag module bolts (1 shown). 8. NOTE: Note the position of the 3 driver air bag module wiring connectors for installation. Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag module. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1623 9. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of the steering column. 10. Open and lower the glove compartment door. 11. Detach the wiring retainer, remove the 4 bolts and the passenger air bag module heat shield. 12. NOTE: Deactivate the passenger air bag module as shown, the canister vent and adaptive tether squibs do not require deactivation. Through the glove compartment opening, disconnect the LH side passenger air bag module electrical connector. 13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector on the LH side. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1624 14. From under the rear of the passenger seat, detach the passenger seat side air bag module electrical connector from the seat track bracket. Then slide and disengage the passenger seat side air bag module electrical connector locking clip, and then release the tab and disconnect the passenger seat side air bag module electrical connector. 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat side air bag module electrical connector. Vehicles without safety canopy modules 16. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy bridge resistor from the safety canopy electrical connector. If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the RCM. If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low resistance fault will be generated by the RCM. Explorer and Mountaineer vehicles with safety canopy modules 17. Release and position aside the passenger side C-pillar trim panel. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1625 18. Disconnect the passenger side safety canopy module electrical connector. 19. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. 20. Release and position aside the driver side C-pillar trim panel. 21. Disconnect the driver side safety canopy module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1626 22. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. Explorer Sport Trac vehicles with safety canopy modules 23. Remove the driver and passenger side upper C-pillar trim panels. 24. Disconnect the passenger side safety canopy module electrical connector. 25. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. 26. Disconnect the driver side safety canopy module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1627 27. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. All vehicles 28. From under the rear of the driver seat, slide and disengage the driver seat side air bag module electrical connector locking clip, and then release the tab and disconnect the driver seat side air bag module electrical connector. 29. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air bag module electrical connector. 30. Install the RCM fuse 17 (10A) to the SJB. 31. Connect the battery ground cable. Reactivation All vehicles 1. Remove the RCM fuse 17 (10A) from the SJB. 2. Disconnect the battery ground cable and wait at least one minute. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1628 3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat side air bag module electrical connector. 4. Connect the driver seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Explorer Sport Trac vehicles with safety canopy modules 5. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 6. Connect the driver side safety canopy module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1629 7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 8. Connect the passenger side safety canopy module electrical connector. 9. Install the driver and passenger upper C-pillar trim panels. Explorer and Mountaineer vehicles with safety canopy modules 10. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 11. Connect the driver side safety canopy module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1630 12. Install the driver side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. 13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 14. Connect the passenger side safety canopy module electrical connector. 15. Install the passenger side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. All vehicles Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1631 16. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat side air bag module electrical connector. 17. Connect the passenger seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Then attach the passenger seat side air bag module electrical connector to the seat track bracket. 18. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector on the LH side. 19. Connect the LH side passenger air bag module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1632 20. Install the passenger air bag module heat shield and the 4 bolts. Attach the wiring retainer. 21. Close glove compartment door. 22. Remove the restraint system diagnostic tools from the clockspring electrical connectors at the top of the steering column. 23. CAUTION: The clockspring electrical connectors are unique and cannot be connected to the driver air bag module in the wrong position. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Connect the driver air bag module electrical connectors as noted in removal. 24. Install the 2 driver air bag module bolts (1 shown). - Tighten to 7 Nm (62 lb-in). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1633 25. 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. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 26. Turn the ignition switch from OFF to ON. 27. Install the RCM fuse 17 (10A) to the SJB and install the cover. 28. 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. 29. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the switch 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 6 seconds and then turn off. If an air bag SRS fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag indicator might not light 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 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 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and occupant classification sensor (OCS) module using a scan tool. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Fuse: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1639 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1640 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1641 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1642 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1643 Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1644 Battery Junction Box (BJB) / Power Distribution Box - Early Production Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1645 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1646 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1647 Battery Junction Box (BJB) / Power Distribution Box - Late Production Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1648 Fuse: Locations Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1651 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1652 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1653 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1654 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1655 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1656 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1657 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1658 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1659 Fuse: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1660 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1661 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1662 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1663 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1664 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1665 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1666 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1667 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Fuse: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1670 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1671 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1672 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1673 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1674 Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1675 Battery Junction Box (BJB) / Power Distribution Box - Early Production Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1676 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1677 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1678 Battery Junction Box (BJB) / Power Distribution Box - Late Production Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1679 Fuse: Application and ID Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Fuse Block: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1684 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1685 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1686 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1687 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1688 Fuse Block: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1689 Battery Junction Box (BJB) / Power Distribution Box - Early Production Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1690 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1691 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1692 Battery Junction Box (BJB) / Power Distribution Box - Late Production Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1693 Fuse Block: Locations Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1696 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1697 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1698 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1699 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1700 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1701 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1702 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1703 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1704 Fuse Block: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1705 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1706 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1707 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1708 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1709 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1710 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1711 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1712 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1713 Fuse Block: Connector Views C1035A C1035B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1714 C2280A Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1715 C2280B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1716 C2280C Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1717 C2280D Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1718 C2280E Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Fuse Block: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1721 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1722 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1723 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1724 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1725 Fuse Block: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1726 Battery Junction Box (BJB) / Power Distribution Box - Early Production Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1727 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1728 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1729 Battery Junction Box (BJB) / Power Distribution Box - Late Production Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1730 Fuse Block: Application and ID Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Relay Box: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1735 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1736 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1737 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1738 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1739 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1740 Battery Junction Box (BJB) / Power Distribution Box - Early Production Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1741 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1742 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1743 Battery Junction Box (BJB) / Power Distribution Box - Late Production Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1744 Relay Box: Locations Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) Relay Box: Diagrams Battery Junction Box (BJB) C1035A C1035B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1747 Relay Box: Diagrams Smart Junction Box (SJB) C2280A Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1748 C2280B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1749 C2280C Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1750 C2280D Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1751 C2280E Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1754 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1755 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1756 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1757 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1758 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1759 Battery Junction Box (BJB) / Power Distribution Box - Early Production Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1760 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1761 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1762 Battery Junction Box (BJB) / Power Distribution Box - Late Production Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1763 Relay Box: Application and ID Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Testing and Inspection Low Tire Pressure Indicator: Testing and Inspection TPMS Indicator and Message Center Messages The TPMS indicator and vehicle message center (if equipped) sometimes displays faults that cannot be resolved by the customer. Treat these messages as TPMS faults that must be serviced. TPMS Indicator Illuminates Continuously NOTE: If the spare tire is in use, the damaged road tire must be repaired and installed on the vehicle to restore complete TPMS functionality before carrying out any diagnosis. 1. The TPMS indicator remains on continuously for this condition: ^ Low Tire Pressure - The TPMS indicator is illuminated solid and the message center displays LOW TIRE PRESSURE (if equipped). This is displayed when any of the tire pressures are low. When this condition exists, the tire pressure must be adjusted to the recommended cold pressure as indicated on the vehicle certification label. 2. NOTE: The TPMS sensors do not transmit when the vehicle is stationary. If the vehicle has been stationary for more than 30 minutes, it will be necessary to wake up the sensors so they will transmit the latest tire pressure information to the SJB. If the vehicle has been stationary for more than 30 minutes, carry out this procedure to wake up the TPMS sensors. 1 Turn the ignition switch to the ON position. 2 Adjust the air pressure in the LF tire. 3 Activate the LF TPMS sensor, at least 2 times, using the tire pressure monitor activation tool. 4 Repeat Steps 2 and 3 for the remaining tires. 5 If the TPMS indicator remains illuminated after adjusting and activating each sensor, GO to Symptom Chart. See: Wheels and Tires/Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures TPMS Indicator Flashes The TPMS indicator flashes for 70 seconds and then remains ON solid when the ignition key is turned to the ON position for these conditions: 1. Tire Pressure Sensor Fault - If equipped, the message center will display TIRE SENSOR FAULT when a tire pressure sensor is malfunctioning. GO to Symptom Chart. See: Wheels and Tires/Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures 2. No communication with the SJB (TPMS is integral to the SJB) - The TPMS indicator is illuminated when the instrument cluster has received no signals from the SJB for more than 5 seconds. If equipped, the message center displays TIRE MONITOR FAULT. GO to Symptom Chart. See: Wheels and Tires/Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures 3. Tire Pressure Monitor Fault - If equipped, the message center will display TIRE MONITOR FAULT when the tire pressure monitoring system is malfunctioning or communication with the instrument cluster has been lost. GO to Symptom Chart. See: Wheels and Tires/Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair Maintenance Required Lamp/Indicator: Service and Repair To reset the oil monitoring system to 100% after each oil change [approximately 5,000 miles (8,000 km) or 180 days] perform the following: 1. Enter SYSTEM CHECK to display HOLD RESET IF NEW OIL. 2. Press and hold the RESET control switch for more than 2 seconds. Oil life is set to 100% and OIL LIFE SET TO 100% is displayed. Note: To change oil life 100% miles value from 5,000 miles (8,000 km) or 180 days to another value, refer to the Oil Life Start Value selected from the SETUP MENU. Oil Life Start Value 1. Select this function from the SETUP MENU for the current display mode. 2. Press and hold the TRIP/RESET control switch to reset oil change. 3. Press the TRIP/RESET control switch for the next SETUP MENU item or wait for more than 4 seconds to return to the INFO MENU. Note: Oil Life Start Value of 100% equals 5,000 miles (8,000 km) and 180 days. Setting Oil Life Start Value to 60% sets the Oil Lift Start Value to 3,000 miles (4,828 km) and 120 days. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) CHECK ENGINE, SERVICE ENGINE SOON, Or ISO Standard Engine Symbol The MIL notifies the driver that the powertrain control module (PCM) has detected an on board diagnostic (OBD) emission-related component or system concern. When this occurs, an OBD diagnostic trouble code (DTC) sets. - The MIL is located in the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE SOON or the international standards organization (ISO) standard engine symbol. - The MIL is illuminated during the instrument cluster prove out for approximately 4 seconds. - The MIL remains illuminated after instrument cluster prove out if: an emission-related concern and DTC exists. - the PCM does not send a control message to the instrument cluster (applications with the MIL controlled through the communication link). - the PCM is operating in the hardware limited operation strategy (HLOS). - The MIL remains off during the instrument cluster prove out if an indicator or instrument cluster concern is present. - To turn off the MIL after a repair, a reset command from the scan tool must be sent, or 3 consecutive drive cycles must be completed without a concern. - For all MIL concerns, go to Symptom Charts. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures - If the MIL flashes at a steady rate, a severe misfire condition may exist. - If the MIL flashes erratically, the PCM can reset while cranking if the battery voltage is low. - The MIL flashes after a period of time with the key in the RUN position (engine not running) if DTC P1000 is set. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair Message Center Configuration Oil Life Reset - Message Center Cluster NOTE:The oil life calculation is set at a maximum of approximately 8,000 km (5,000 miles) or 180 days 1. Press and release the SETUP button until the message center displays PRESS RESET TO BEGIN SYSTEM CHECK. 2. Press and release the RESET button until the message center displays HOLD RESET IF NEW OIL. 3. Press and hold the RESET button for 2 seconds and release to reset the oil life to 100%. 4. The message center displays SETUP MENU HOLD RESET. Oil Life Reset - Base Instrument Cluster NOTE: The oil life calculation is set at a maximum of approximately 8,000 km (5,000 miles) or 180 days. 1. Place the ignition in the RUN position with the engine off (KOEO). 2. Press and release the TRIP/RESET button until SETUP MENU HOLD RESET is displayed. 3. Press and hold the TRIP/RESET button until SYSTEM CHECK is displayed. 4. Release the TRIP/RESET button. 5. Press and release the TRIP/RESET button to scroll through the system check menu items until HOLD RESET IF NEW OIL is displayed. 6. Press and hold the TRIP/RESET button until OIL LIFE SET TO 100% is displayed. 7. Release the TRIP/RESET button. The oil life is now reset. Oil Life Start Value - Message Center Cluster NOTE:The oil life start value is used to reset the oil life value back to the maximum of approximately 8,000 km (5,000 miles) if the value was previously changed or to lower the value from the maximum (8,000 km To reset the oil monitoring system to 100% after each oil change [approximately 5,000 miles (8,000 km) or 180 days] perform the following: 1. Enter SYSTEM CHECK to display "OIL XXX% OIL LIFE OK". 2. Press RESET control to display "HOLD RESET IF NEW OIL". 3. Press and hold RESET control for more than 2 seconds. Oil life is set to 100% and "OIL CHANGE SET TO 100%" is displayed. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation JACKING WARNING: - 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 correctly located to prevent the vehicle from falling. CAUTION: - A wheel chock should be used to prevent the vehicle from rolling and falling off the jack. - Position the jack to avoid contact with the fuel tank. The following offers general guidelines for vehicle jacking. Additionally, jack manufacturers offer their own operating precautions. Be sure to read and understand operating instructions for the jacking equipment before use. Jacking Points NOTE: Place a wheel chock diagonally opposite of the wheel to be raised. The front jacking points are indicated by a cut-out in the frame, located behind the front tire and wheel. CAUTION: Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and adjoining differential housing Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 1781 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. The rear jacking points are indicated by a cut-out in the frame in front of the rear tire and wheel. LIFTING Lifting Points 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. - 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. - Position the hoist adapters to avoid contact with the fuel tank. - To avoid damage to the suspension, do not position the hoist adapters on the rear trailing arm brackets. NOTE: Explorer shown, Explorer Sport Trac similar. The following offers general guidelines for vehicle lifting. Additionally, hoist manufacturers offer their own operating precautions. Be sure to read and understand operating instructions for the lifting equipment before use. Position the hoist directly under the frame rails. Position the hoist directly under the frame rails. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Special Tool(s) NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the Smart Junction Box (SJB). NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire Pressure Monitoring System (TPMS). Radio frequency noise is generated by electrical motors and appliance operation, cellular telephones, remote transmitters, power inverters and portable entertainment equipment. NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor again. NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire procedure must be repeated. NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for front and rear tires, tire rotation will not affect the system. 1. Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. - The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire Pressure Monitor Activation Tool must remain in place 180 degrees from the valve stem. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 1786 6. Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press and release the test button on the Tire Pressure Monitor Activation Tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB. 7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF tire sidewall opposite (180 degrees) from the valve stem and press and release the test button to train the RF tire pressure sensor. NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and the entire procedure must be repeated. 8. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor identifiers trained to the SJB and document them on the applicable warranty claim. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed SJB. 10. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and carry out the SJB On-Demand Self Test. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Disassembly CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor can be removed and installed without removing the strap or the cradle. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. 1. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. 2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip can occur. Using a pocket screwdriver, or similar tool, remove the sensor locking clip. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1789 3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor can occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. 4. Remove the sensor. Assembly 1. CAUTION: Damage to the sensor can occur if excessive force is applied during sensor installation. NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise when correctly seated. Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the sensor locking clip cannot be fully inserted, then the sensor may not be fully seated on the cradle or the locking clip may be inserted backward. Insert a new locking clip into the sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1790 3. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Training. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1791 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Material Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1792 Disassembly CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There are several different strap kits available based on wheel diameter but all strap kits share the same base part number. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. 1. Remove the tire pressure monitoring system (TPMS) sensor. 2. WARNING: The TPMS band is under tension. Always use safety goggles or a face shield and gloves when removing the TPMS band/strap. Failure to follow these instructions may result in personal injury. Remove a factory installed strap in this sequence: 1 Locate the strap buckle and secure the strap to the wheel using duct tape or a similar item, on both sides of the buckle approximately 25 mm (0.98 inch) from the buckle. 2 Using a large screwdriver and a twisting motion, unbuckle the strap. 3 Discard the strap. To remove a dealer installed strap, turn the worm gear screw until the strap is fully released from the worm gear. ^ Discard the strap. 3. NOTE: To aid assembly, mark the location of the cradle prior to disassembly. Using a screwdriver, or similar tool, remove the cradle by inserting the screwdriver under the cradle and prying up. Assembly 1. NOTE: Make sure the sensor is fully seated into the new cradle. The sensor will make a "click" noise when fully seated. Position the sensor into the new cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. CAUTION: Metal scrapers can damage the wheel. Use only plastic or non-metallic scrapers to remove the cradle adhesive strip residue. NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the valve stem. Clean the area where the sensor and cradle are to be installed. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1793 3. NOTE: The sensor and cradle must be positioned with the hinge side of the sensor on the RH side when viewed from the curb side (beauty side) of the wheel. NOTE: The sensor has raised markings indicating how to position the sensor. Remove the adhesive tape liner from the cradle and position the sensor and cradle into the wheel drop well 180° from the valve stem. 4. Install the tapered end of the strap through the opening of the cradle on the hinge side of the sensor. This will position the worm gear on the locking clip side of the sensor. 5. CAUTION: Steel wheels have a "high spot" along their circumference. Make sure the strap is positioned in the lowest spot possible for correct sensor and cradle retention. NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear. Position the worm gear 13 - 26 mm (0.5 - 1.0 inch) away from the sensor and tighten the worm gear. ^ Tighten to 3 Nm (27 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1794 6. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Training. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Testing and Inspection Low Tire Pressure Indicator: Testing and Inspection TPMS Indicator and Message Center Messages The TPMS indicator and vehicle message center (if equipped) sometimes displays faults that cannot be resolved by the customer. Treat these messages as TPMS faults that must be serviced. TPMS Indicator Illuminates Continuously NOTE: If the spare tire is in use, the damaged road tire must be repaired and installed on the vehicle to restore complete TPMS functionality before carrying out any diagnosis. 1. The TPMS indicator remains on continuously for this condition: ^ Low Tire Pressure - The TPMS indicator is illuminated solid and the message center displays LOW TIRE PRESSURE (if equipped). This is displayed when any of the tire pressures are low. When this condition exists, the tire pressure must be adjusted to the recommended cold pressure as indicated on the vehicle certification label. 2. NOTE: The TPMS sensors do not transmit when the vehicle is stationary. If the vehicle has been stationary for more than 30 minutes, it will be necessary to wake up the sensors so they will transmit the latest tire pressure information to the SJB. If the vehicle has been stationary for more than 30 minutes, carry out this procedure to wake up the TPMS sensors. 1 Turn the ignition switch to the ON position. 2 Adjust the air pressure in the LF tire. 3 Activate the LF TPMS sensor, at least 2 times, using the tire pressure monitor activation tool. 4 Repeat Steps 2 and 3 for the remaining tires. 5 If the TPMS indicator remains illuminated after adjusting and activating each sensor, GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures TPMS Indicator Flashes The TPMS indicator flashes for 70 seconds and then remains ON solid when the ignition key is turned to the ON position for these conditions: 1. Tire Pressure Sensor Fault - If equipped, the message center will display TIRE SENSOR FAULT when a tire pressure sensor is malfunctioning. GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures 2. No communication with the SJB (TPMS is integral to the SJB) - The TPMS indicator is illuminated when the instrument cluster has received no signals from the SJB for more than 5 seconds. If equipped, the message center displays TIRE MONITOR FAULT. GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures 3. Tire Pressure Monitor Fault - If equipped, the message center will display TIRE MONITOR FAULT when the tire pressure monitoring system is malfunctioning or communication with the instrument cluster has been lost. GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Special Tool(s) NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the Smart Junction Box (SJB). NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire Pressure Monitoring System (TPMS). Radio frequency noise is generated by electrical motors and appliance operation, cellular telephones, remote transmitters, power inverters and portable entertainment equipment. NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor again. NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire procedure must be repeated. NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for front and rear tires, tire rotation will not affect the system. 1. Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. - The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire Pressure Monitor Activation Tool must remain in place 180 degrees from the valve stem. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 1802 6. Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press and release the test button on the Tire Pressure Monitor Activation Tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB. 7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF tire sidewall opposite (180 degrees) from the valve stem and press and release the test button to train the RF tire pressure sensor. NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and the entire procedure must be repeated. 8. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor identifiers trained to the SJB and document them on the applicable warranty claim. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed SJB. 10. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and carry out the SJB On-Demand Self Test. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Disassembly CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor can be removed and installed without removing the strap or the cradle. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. 1. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. 2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip can occur. Using a pocket screwdriver, or similar tool, remove the sensor locking clip. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1805 3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor can occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. 4. Remove the sensor. Assembly 1. CAUTION: Damage to the sensor can occur if excessive force is applied during sensor installation. NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise when correctly seated. Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the sensor locking clip cannot be fully inserted, then the sensor may not be fully seated on the cradle or the locking clip may be inserted backward. Insert a new locking clip into the sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1806 3. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Training. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1807 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Material Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1808 Disassembly CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There are several different strap kits available based on wheel diameter but all strap kits share the same base part number. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. 1. Remove the tire pressure monitoring system (TPMS) sensor. 2. WARNING: The TPMS band is under tension. Always use safety goggles or a face shield and gloves when removing the TPMS band/strap. Failure to follow these instructions may result in personal injury. Remove a factory installed strap in this sequence: 1 Locate the strap buckle and secure the strap to the wheel using duct tape or a similar item, on both sides of the buckle approximately 25 mm (0.98 inch) from the buckle. 2 Using a large screwdriver and a twisting motion, unbuckle the strap. 3 Discard the strap. To remove a dealer installed strap, turn the worm gear screw until the strap is fully released from the worm gear. ^ Discard the strap. 3. NOTE: To aid assembly, mark the location of the cradle prior to disassembly. Using a screwdriver, or similar tool, remove the cradle by inserting the screwdriver under the cradle and prying up. Assembly 1. NOTE: Make sure the sensor is fully seated into the new cradle. The sensor will make a "click" noise when fully seated. Position the sensor into the new cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. CAUTION: Metal scrapers can damage the wheel. Use only plastic or non-metallic scrapers to remove the cradle adhesive strip residue. NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the valve stem. Clean the area where the sensor and cradle are to be installed. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1809 3. NOTE: The sensor and cradle must be positioned with the hinge side of the sensor on the RH side when viewed from the curb side (beauty side) of the wheel. NOTE: The sensor has raised markings indicating how to position the sensor. Remove the adhesive tape liner from the cradle and position the sensor and cradle into the wheel drop well 180° from the valve stem. 4. Install the tapered end of the strap through the opening of the cradle on the hinge side of the sensor. This will position the worm gear on the locking clip side of the sensor. 5. CAUTION: Steel wheels have a "high spot" along their circumference. Make sure the strap is positioned in the lowest spot possible for correct sensor and cradle retention. NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear. Position the worm gear 13 - 26 mm (0.5 - 1.0 inch) away from the sensor and tighten the worm gear. ^ Tighten to 3 Nm (27 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1810 6. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Training. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 09-14-1 > Jul > 09 > Wheels - 17 Inch Polished Wheel Clearcoat Cracking Wheels: Customer Interest Wheels - 17 Inch Polished Wheel Clearcoat Cracking TSB 09-14-1 07/27/09 17 INCH BRIGHT MACHINED WHEEL - CORROSION AND ETCHING FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles and equipped with 17 inch aluminum wheels may exhibit the clear coat peeling off the wheel or cracks in the clear coat that look like spider webs. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Please review the illustrations of an affected wheel. (Figures 1 and 2) 2. To service, replace only affected wheel or wheels. Refer to Workshop Manual, Section 204-04 for wheel removal and installation procedures including tire pressure monitoring system (TPMS) sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 09-14-1 > Jul > 09 > Wheels - 17 Inch Polished Wheel Clearcoat Cracking > Page 1819 Parts Block 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 091401A 2006-2010 Explorer, 0.6 Hr. Mountaineer, 2007-2010 Explorer Sport Trac: Replace One (1) wheel Includes Time To Transfer TPMS, And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1) 091401B 2006-2010 Explorer, 0.8 Hr. Mountaineer, 2007-2010 Explorer Sport Trac: Replace Two (2) Wheels Includes Time To Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 091401C 2006-2010 Explorer, 1.1 Hrs. Mountaineer, 2007-2010 Explorer Sport Trac: Replace Three (3) Wheels Includes Time To Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 091401D 2006-2010 Explorer, 1.3 Hrs. Mountaineer, 2007-2010 Explorer Sport Trac: Replace Four (4) Wheels Includes Time To Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) DEALER CODING CONDITION BASIC PART NO. CODE 1007 91 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At Low Speeds Wheels: Customer Interest Wheels/Tires - Popping/Snapping Noise At Low Speeds TSB 09-11-2 06/15/09 POPPING/SNAPPING NOISE - FRONT OR REAR 18 INCH WHEELS - TURNING AT SLOW SPEED BELOW 10 MPH (16 KM/H) FORD: 2007-2008 Edge, Explorer Sport Trac, Explorer LINCOLN: 2007-2008 MKX MERCURY: 2007-2008 Mountaineer This article supersedes TSB 09-4-3 to update the vehicle model years. ISSUE Some 2007-2008 Explorer, Sport Trac, and Mountaineer vehicles built prior to 1/28/2008 and 2007-2008 Edge and MKX vehicles built prior to 8/18/2008 and equipped with 18 inch wheels may exhibit a noise coming from the front or rear wheel(s) while turning the steering wheel at speeds lower than 10 MPH (16 Km/h). The noise may be coming from the chrome cladding that attaches to the rim. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IF THE SOURCE OF NOISE IS NOT FROM THE WHEEL, FOLLOW NORMAL WORKSHOP MANUAL PROCEDURES. 1. Verify the noise is coming from the wheel(s). 2. Replace the wheel(s) that have the noise with updated service parts. Refer to Workshop Manual (WSM), Section 204-04. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At Low Speeds > Page 1824 3. Lubricate the remaining wheels at the outboard wheel flange, between the cladding and the wheel inter[ace. Use Motorcraft(R) Silicone Spray Lubricant with an extension nozzle. (Figures 1 and 2) 4. Clean any excess lubricant off the wheel with a soft cloth. Parts Block 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 091102A 2007-2008 Explorer, 0.9 Hr. Explorer Sport Trac, Mountaineer, 2007 Edge, MKX: Replace One Wheel and Lubricate Remaining Three Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1) 091102B 2007-2008 Explorer, 1.1 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge, MKX: Replace Two Wheels and Lubricate Remaining Two Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 091102C 2007-2008 Explorer, 1.4 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge, Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At Low Speeds > Page 1825 MKX: Replace Three Wheels and Lubricate Remaining Wheel. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), Balance And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 091102D 2007-2008 Explorer, 1.6 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge, MKX: Replace Four Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) DEALER CODING CONDITION BASIC PART NO. CODE 1007 68 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels When Turning Wheels: Customer Interest Wheels/Tires - Popping Noise From Wheels When Turning TSB 07-23-4 11/26/07 POPPING/SNAPPING NOISE - FRONT OR REAR 18 INCH WHEELS - TURNING AT SLOW SPEEDS BELOW 10 MPH (16KM/H) FORD: 2007 Edge 2007-2008 Explorer Sport Trac, Explorer MERCURY: 2007-2008 Mountaineer This article supersedes TSB 07-19-6 to update the vehicle lines. ISSUE Some 2007-2008 Explorer, Explorer Sport Trac and Mountaineer vehicles built prior to 8/17/2007 and 2007 Edge vehicles built prior to 8/24/2007 and equipped with 18" wheels may exhibit noise coming from the front or rear wheel(s) while turning the steering wheel at speeds lower than 10 MPH (16 Km/h). The noise may be coming from the chrome cladding that attaches to the rim. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IF THE SOURCE OF NOISE IS NOT FROM THE WHEEL, FOLLOW NORMAL WORKSHOP MANUAL PROCEDURES. 1. Verify the noise is coming from the wheel(s). 2. Replace wheel(s) with updated service parts for 18" Chrome (Bright) Clad Cast Aluminum wheel and Satin Clad Cast Aluminum wheel(s). Refer to Workshop Manual (WSM), Section 204-04. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels When Turning > Page 1830 3. Lubricate the remaining wheels at the outboard wheel flange, between the cladding and the wheel inter[ace. Use Motorcraft Silicone Spray Lubricant and spray lubricant with an extension nozzle. (Figures 1 and 2) NOTE NEW WHEELS WILL NOT REQUIRE LUBRICATION. 4. Clean any excess lubricate off the wheel with a soft cloth. 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 072304A 2007-2008 Explorer, 0.9 Hr. Explorer Sport Trac, Mountaineer, 2007 Edge: Replace One Wheel and Lubricate Remaining Three Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1) 072304B 2007-2008 Explorer, 1.1 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge: Replace Two Wheels and Lubricate Remaining Two Wheels. Includes Test Drive, Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 072304C 2007-2008 Explorer, 1.4 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge: Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels When Turning > Page 1831 Replace Three Wheels and Lubricate Remaining Wheel. Includes Test Drive, Transfer TPMS, Balance And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 072304D 2007-2008 Explorer, 1.6 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge: Replace Four Wheels. Includes Test Drive, Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) DEALER CODING CONDITION BASIC PART NO. CODE 1007 68 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 07-12-2 > Jun > 07 > Wheels - 16 Inch Wheel Clear Coat Peeling/Cracking Wheels: Customer Interest Wheels - 16 Inch Wheel Clear Coat Peeling/Cracking TSB 07-12-2 06/25/07 16 INCH BRIGHT MACHINED WHEEL-CORROSION AND ETCHING FORD: 2006-2007 Explorer 2007 Explorer Sport Trac ISSUE Some 2006-2007 Explorer and 2007 Explorer Sport Trac vehicles equipped with 16 inch wheels may exhibit the clear coat peeling off the wheel or cracks in the clear coat that look like spider webs. ACTION Replace affected wheel or wheels with new wheels that have added corrosion protection. SERVICE PROCEDURE Please review illustration shown below. To service, replace only affected wheel or wheels. Refer to Workshop Manual Section 204-04 for wheel removal and installation procedures. See example of affected wheel in Figure 1. Parts Block 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 071202A 2006-2007 Explorer, 2007 0.5 Hr. Explorer Sport Trac: Replace One Wheel, Includes Time To Transfer Tire Pressure Monitor Sensor (TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1, 1552A, 1007D3) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 07-12-2 > Jun > 07 > Wheels - 16 Inch Wheel Clear Coat Peeling/Cracking > Page 1836 071202B 2006-2007 Explorer, 2007 0.7 Hr. Explorer Sport Trac: Replace Two Wheels, Includes Time To Transfer Tire Pressure Monitor Sensor (TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1, 1552A, 1007D3) 071202C 2006-2007 Explorer, 2007 1.0 Hr. Explorer Sport Trac: Replace Three Wheels, Includes Time To Transfer Tire Pressure Monitor Sensor (TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1, 1552A, 1007D3) 071202D 2006-2007 Explorer, 2007 1.2 Hrs. Explorer Sport Trac: Replace All Wheels, Includes Time To Transfer Tire Pressure Monitor Sensor (TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1, 1552A, 1007D3) DEALER CODING CONDITION BASIC PART NO. CODE 1007 D4 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 09-14-1 > Jul > 09 > Wheels - 17 Inch Polished Wheel Clearcoat Cracking Wheels: All Technical Service Bulletins Wheels - 17 Inch Polished Wheel Clearcoat Cracking TSB 09-14-1 07/27/09 17 INCH BRIGHT MACHINED WHEEL - CORROSION AND ETCHING FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles and equipped with 17 inch aluminum wheels may exhibit the clear coat peeling off the wheel or cracks in the clear coat that look like spider webs. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Please review the illustrations of an affected wheel. (Figures 1 and 2) 2. To service, replace only affected wheel or wheels. Refer to Workshop Manual, Section 204-04 for wheel removal and installation procedures including tire pressure monitoring system (TPMS) sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 09-14-1 > Jul > 09 > Wheels - 17 Inch Polished Wheel Clearcoat Cracking > Page 1842 Parts Block 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 091401A 2006-2010 Explorer, 0.6 Hr. Mountaineer, 2007-2010 Explorer Sport Trac: Replace One (1) wheel Includes Time To Transfer TPMS, And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1) 091401B 2006-2010 Explorer, 0.8 Hr. Mountaineer, 2007-2010 Explorer Sport Trac: Replace Two (2) Wheels Includes Time To Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 091401C 2006-2010 Explorer, 1.1 Hrs. Mountaineer, 2007-2010 Explorer Sport Trac: Replace Three (3) Wheels Includes Time To Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 091401D 2006-2010 Explorer, 1.3 Hrs. Mountaineer, 2007-2010 Explorer Sport Trac: Replace Four (4) Wheels Includes Time To Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) DEALER CODING CONDITION BASIC PART NO. CODE 1007 91 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At Low Speeds Wheels: All Technical Service Bulletins Wheels/Tires - Popping/Snapping Noise At Low Speeds TSB 09-11-2 06/15/09 POPPING/SNAPPING NOISE - FRONT OR REAR 18 INCH WHEELS - TURNING AT SLOW SPEED BELOW 10 MPH (16 KM/H) FORD: 2007-2008 Edge, Explorer Sport Trac, Explorer LINCOLN: 2007-2008 MKX MERCURY: 2007-2008 Mountaineer This article supersedes TSB 09-4-3 to update the vehicle model years. ISSUE Some 2007-2008 Explorer, Sport Trac, and Mountaineer vehicles built prior to 1/28/2008 and 2007-2008 Edge and MKX vehicles built prior to 8/18/2008 and equipped with 18 inch wheels may exhibit a noise coming from the front or rear wheel(s) while turning the steering wheel at speeds lower than 10 MPH (16 Km/h). The noise may be coming from the chrome cladding that attaches to the rim. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IF THE SOURCE OF NOISE IS NOT FROM THE WHEEL, FOLLOW NORMAL WORKSHOP MANUAL PROCEDURES. 1. Verify the noise is coming from the wheel(s). 2. Replace the wheel(s) that have the noise with updated service parts. Refer to Workshop Manual (WSM), Section 204-04. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At Low Speeds > Page 1847 3. Lubricate the remaining wheels at the outboard wheel flange, between the cladding and the wheel inter[ace. Use Motorcraft(R) Silicone Spray Lubricant with an extension nozzle. (Figures 1 and 2) 4. Clean any excess lubricant off the wheel with a soft cloth. Parts Block 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 091102A 2007-2008 Explorer, 0.9 Hr. Explorer Sport Trac, Mountaineer, 2007 Edge, MKX: Replace One Wheel and Lubricate Remaining Three Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1) 091102B 2007-2008 Explorer, 1.1 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge, MKX: Replace Two Wheels and Lubricate Remaining Two Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 091102C 2007-2008 Explorer, 1.4 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge, Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At Low Speeds > Page 1848 MKX: Replace Three Wheels and Lubricate Remaining Wheel. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), Balance And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 091102D 2007-2008 Explorer, 1.6 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge, MKX: Replace Four Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) DEALER CODING CONDITION BASIC PART NO. CODE 1007 68 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels When Turning Wheels: All Technical Service Bulletins Wheels/Tires - Popping Noise From Wheels When Turning TSB 07-23-4 11/26/07 POPPING/SNAPPING NOISE - FRONT OR REAR 18 INCH WHEELS - TURNING AT SLOW SPEEDS BELOW 10 MPH (16KM/H) FORD: 2007 Edge 2007-2008 Explorer Sport Trac, Explorer MERCURY: 2007-2008 Mountaineer This article supersedes TSB 07-19-6 to update the vehicle lines. ISSUE Some 2007-2008 Explorer, Explorer Sport Trac and Mountaineer vehicles built prior to 8/17/2007 and 2007 Edge vehicles built prior to 8/24/2007 and equipped with 18" wheels may exhibit noise coming from the front or rear wheel(s) while turning the steering wheel at speeds lower than 10 MPH (16 Km/h). The noise may be coming from the chrome cladding that attaches to the rim. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IF THE SOURCE OF NOISE IS NOT FROM THE WHEEL, FOLLOW NORMAL WORKSHOP MANUAL PROCEDURES. 1. Verify the noise is coming from the wheel(s). 2. Replace wheel(s) with updated service parts for 18" Chrome (Bright) Clad Cast Aluminum wheel and Satin Clad Cast Aluminum wheel(s). Refer to Workshop Manual (WSM), Section 204-04. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels When Turning > Page 1853 3. Lubricate the remaining wheels at the outboard wheel flange, between the cladding and the wheel inter[ace. Use Motorcraft Silicone Spray Lubricant and spray lubricant with an extension nozzle. (Figures 1 and 2) NOTE NEW WHEELS WILL NOT REQUIRE LUBRICATION. 4. Clean any excess lubricate off the wheel with a soft cloth. 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 072304A 2007-2008 Explorer, 0.9 Hr. Explorer Sport Trac, Mountaineer, 2007 Edge: Replace One Wheel and Lubricate Remaining Three Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1) 072304B 2007-2008 Explorer, 1.1 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge: Replace Two Wheels and Lubricate Remaining Two Wheels. Includes Test Drive, Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 072304C 2007-2008 Explorer, 1.4 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge: Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels When Turning > Page 1854 Replace Three Wheels and Lubricate Remaining Wheel. Includes Test Drive, Transfer TPMS, Balance And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 072304D 2007-2008 Explorer, 1.6 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge: Replace Four Wheels. Includes Test Drive, Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) DEALER CODING CONDITION BASIC PART NO. CODE 1007 68 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 07-12-2 > Jun > 07 > Wheels - 16 Inch Wheel Clear Coat Peeling/Cracking Wheels: All Technical Service Bulletins Wheels - 16 Inch Wheel Clear Coat Peeling/Cracking TSB 07-12-2 06/25/07 16 INCH BRIGHT MACHINED WHEEL-CORROSION AND ETCHING FORD: 2006-2007 Explorer 2007 Explorer Sport Trac ISSUE Some 2006-2007 Explorer and 2007 Explorer Sport Trac vehicles equipped with 16 inch wheels may exhibit the clear coat peeling off the wheel or cracks in the clear coat that look like spider webs. ACTION Replace affected wheel or wheels with new wheels that have added corrosion protection. SERVICE PROCEDURE Please review illustration shown below. To service, replace only affected wheel or wheels. Refer to Workshop Manual Section 204-04 for wheel removal and installation procedures. See example of affected wheel in Figure 1. Parts Block 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 071202A 2006-2007 Explorer, 2007 0.5 Hr. Explorer Sport Trac: Replace One Wheel, Includes Time To Transfer Tire Pressure Monitor Sensor (TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1, 1552A, 1007D3) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 07-12-2 > Jun > 07 > Wheels - 16 Inch Wheel Clear Coat Peeling/Cracking > Page 1859 071202B 2006-2007 Explorer, 2007 0.7 Hr. Explorer Sport Trac: Replace Two Wheels, Includes Time To Transfer Tire Pressure Monitor Sensor (TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1, 1552A, 1007D3) 071202C 2006-2007 Explorer, 2007 1.0 Hr. Explorer Sport Trac: Replace Three Wheels, Includes Time To Transfer Tire Pressure Monitor Sensor (TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1, 1552A, 1007D3) 071202D 2006-2007 Explorer, 2007 1.2 Hrs. Explorer Sport Trac: Replace All Wheels, Includes Time To Transfer Tire Pressure Monitor Sensor (TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1, 1552A, 1007D3) DEALER CODING CONDITION BASIC PART NO. CODE 1007 D4 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Wheel Bearing and Wheel Hub Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number or an equivalent part must be installed, if installation is necessary. Do not use a part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose can occur. Remove the bolts and position the caliper, pads and anchor plate assembly aside. ^ Discard the bolts. ^ Support the caliper and anchor plate assembly using mechanic's wire. ^ To install, tighten to 165 Nm (122 ft. lbs.) 3. Remove the brake disc. 4. CAUTION: Inspect and if necessary, clean area around wheel speed sensor before removing it from the wheel bearing and hub. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1864 Remove the wheel speed sensor bolt and disconnect the wheel speed sensor from the wheel bearing and hub assembly. ^ To install, tighten to 18 Nm (13 ft. lbs.) 5. Remove the 3 bolts and the wheel bearing and hub assembly. ^ Discard the bolts. ^ To install, tighten to 122 Nm (90 ft. lbs.) 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1865 Wheel Bearing: Service and Repair Rear Wheel Bearing and Wheel Hub Special Tool(s) Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Remove the wheel knuckle. 2. Remove the 3 brake disc shield bolts. ^ To install, tighten to 8 Nm (71 inch lbs.) 3. Using the special tool and a suitable press, remove the wheel hub. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1866 4. Remove the snap ring. 5. Using a suitable press and adapters, remove the wheel bearing. 6. To install, reverse the removal procedure. 7. Install the wheel knuckle. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Testing and Inspection > Driveline System Wheel Hub: Testing and Inspection Driveline System Inspection and Verification Certain axle and driveline symptoms are also common to the engine, transmission, wheel bearings, tires and other parts of the vehicle. For this reason, be sure that the cause of the concern is in the axle before disassembling, adjusting or repairing the axle. Refer to Vehicle/Testing and Inspection. Certain driveshaft vibration symptoms are common to the front engine accessory drive (FEAD), the engine, transmission or tires. Be sure the cause of the concern is the driveshaft before repairing or installing a new driveshaft. Refer to Vehicle/Testing and Inspection. Noise Acceptability A gear-driven unit will produce a certain amount of noise. Some noise is acceptable and audible at certain speeds or under various driving conditions, such as a newly paved blacktop road. Slight noise is not detrimental to the operation of the axle and is considered normal. Universal Joint (U-Joint) Inspection Place the vehicle on a frame hoist and rotate the driveshaft by hand. Check for rough operation or seized U-joints. Install a new U-joint if it shows signs of seizure, excessive wear or incorrect seating. Analysis of Leakage Clean up the leaking area enough to identify the exact source. An axle leak can be caused by: ^ Axle lubricant level is too high ^ Worn or damaged axle shaft seals or differential seals ^ Differential housing is cracked ^ Flange yoke seal is worn or damaged ^ Pinion flange is scored or damaged ^ Axle cover is not sealed ^ Vent is plugged Repair the axle as necessary. Make sure the axle lubricant is at the correct level. Axle Vent NOTE: If a plugged vent cannot be cleared, install a new vent. NOTE: If the vent is removed from the housing for any reason, a new vent must be installed. A plugged vent will cause excessive seal lip wear due to internal pressure buildup. If a leak occurs, check the vent. Make sure the vent hose is not kinked. Remove the hose from the vent nipple and clear the hose of any foreign material. While the hose is removed, pass a length of mechanic's wire or a small diameter Allen wrench in and out of the vent to clean it. Connect the hose when done. Flange Yoke Seal Leaks at the axle drive pinion seal originate for these reasons: ^ The seal is not correctly installed ^ A poor quality seal journal surface Any damage to the seal bore (dings, dents, gouges or other imperfections) will distort the seal casing and allow leakage past the outer edge of the axle drive pinion seal. The axle drive pinion seal can be torn, cut or gouged if it is not installed carefully. The spring that holds the axle drive pinion seal against the pinion flange can be knocked out, which can allow leakage past the lip. The rubber lips can occasionally become hard (like plastic) with cracks at the oil lip contact point. The contact point on the pinion flange may blacken, indicating excessive heat. Marks, nicks, gouges or rough surface texture on the seal journal of the pinion flange will also cause leaks. A new pinion flange must be installed if any of these conditions exist. Metal chips or sand trapped at the sealing lip can also cause oil leaks. This can cause a wear groove on the pinion flange and heavy pinion seal wear. When a seal leak occurs, install a new seal and check the vent and the vent hose to make sure they are clean and free of foreign material. Analysis of Vibration WARNING: An all-wheel drive (AWD) vehicle will always have all wheels (on both axles) driving. If only one wheel/axle is raised off the floor and the axle is driven by the engine, the wheel/axle on the floor could drive the vehicle off the stand or jack. Be sure all wheels are off the floor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Testing and Inspection > Driveline System > Page 1871 Few vibration conditions are caused by the front or rear axle. For a vibration concern, follow the diagnosis procedure in Vehicle/Testing and Inspection unless there is a good reason to suspect the axle. Tires WARNING: Do not balance the wheels and tires while they are mounted on the vehicle. Possible tire disintegration or differential failure could result, causing personal injury or extensive component damage. Use an off-vehicle wheel and tire balancer only. Most vibration is caused by tires, driveline angle or driveline imbalance. Vibration is a concern with modern, high-mileage tires if they are not "true" both radially and laterally. They are more susceptible to vibration around the limits of radial and lateral runout of the tire and wheel assembly. They also require more accurate balancing. Wheel and tire runout checks, truing and balancing are normally done before axle inspection. Driveline Imbalance Driveline imbalance can be caused by excessive looseness in the driveshaft, damaged driveshaft tubing, looseness or high runout at the driveshaft attachments (axle and transfer case flanges). Excessive looseness in the driveshaft can be caused by CV joint or universal joint wear, as well as loose fitting slip-yoke splines. Inspect and install new driveshaft components as necessary. Driveline Angle Driveline Angle Driveline angularity is the angular relationship between the engine crankshaft, the driveshaft and the rear axle pinion. Some of the factors determining driveline angularity include ride height, rear spring and engine mounts. An incorrect driveline (pinion) angle can often be detected by examining the driving condition in which the vibration occurs. ^ A vibration during coastdown, from 72 to 56 km/h (45 to 35 mph), is often caused by an excessive U-joint angle at the axle (pinion nose downward). ^ A vibration during acceleration, from 56 to 72 km/h (35 to 45 mph), may indicate an excessive U-joint angle at the axle (pinion nose upward). When these conditions exist, check the driveline angles. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Testing and Inspection > Driveline System > Page 1872 Universal Joint (U-Joint) Wear Place the vehicle on a frame hoist and rotate the driveshaft by hand. Check for rough operation or seized U-joints. Install a new U-joint if it shows signs of seizure, excessive wear or incorrect seating. Wheel Hub Bolt Circle Runout NOTE: The brake discs must be removed to carry out all runout measurements. 1. Position the special tool on the wheel hub bolt, as close to the hub face as possible. Zero the indicator to allow the pointer to deflect either way. 2. Rotate the hub until the next bolt is contacted. Record the measurement and continue until each bolt is checked. The difference between the maximum and minimum contact readings will be the total wheel hub bolt circle runout. The runout must not exceed 0.38 mm (0.015 inch). Pilot Runout 1. Position the special tools on the pilot, as close to the hub as possible. Zero the indicator to allow the pointer to deflect either way. 2. Rotate the hub one full turn and note the maximum and minimum readings. The difference between the maximum and minimum readings will be the total pilot runout. Pilot runout must not exceed 0.15 mm (0.006 inch). Wheel Hub Runout 1. Position the special tool on the wheel hub, as close to the outer edge as possible. Zero the indicator to allow the pointer to deflect either way. 2. Rotate the hub one full turn and note the maximum and minimum readings. The difference between the maximum and minimum readings will be the total wheel hub runout. The runout must not exceed 0.127 mm (0.005 inch). Drive Pinion Stem and Pinion Flange Check the pinion flange runout when all other checks have failed to show the cause of the vibration. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Testing and Inspection > Driveline System > Page 1873 One cause of excessive pinion flange runout is incorrect installation of the axle drive pinion seal. Check to determine if the spring on the seal lip has been dislodged. Halfshafts NOTE: Constant velocity (CV) joints must not be installed unless disassembly and inspection reveals unusual wear. NOTE: While inspecting the boots, watch for indentations ("dimples") in the boot convolutions. Indentations must be removed. ^ Inspect the boots for evidence of cracks, tears or splits. ^ Inspect the underbody for any indication of grease splatter near the boots outboard and inboard locations. This is an indication of boot/clamp damage. Axle Noise NOTE: Before disassembling the axle to diagnose and correct gear noise, eliminate the tires, exhaust, trim items, roof racks and wheel bearings as possible causes. Follow the diagnostic procedures in Vehicle/Testing and Inspection. The noises described as follows usually have specific causes that can be diagnosed by observation as the unit is disassembled. The initial clues are the type of noise heard during the road test. Gear Howl and Whine Howling or whining of the ring gear and pinion is due to an incorrect gear pattern, gear damage or incorrect bearing preload. Bearing Whine Bearing whine is a high-pitched sound similar to a whistle. It is usually caused by worn/damaged pinion bearings, which are operating at driveshaft speed. Bearing noise occurs at all driving speeds. This distinguishes it from gear whine which usually comes and goes as speed changes. As noted, pinion bearings make a high-pitched, whistling noise, usually at all speeds. If however there is only one pinion bearing that is worn/damaged, the noise may vary in different driving phases. New pinion bearings must not be installed unless they are scored or damaged, or there is a specific pinion bearing noise. A worn/damaged bearing will normally be obvious at disassembly. Examine the large end of the rollers for wear. If the pinion bearings original blend radius has worn to a sharp edge, a new pinion bearing must be installed. A wheel bearing noise can be mistaken for a pinion bearing noise. On rear wheel drive (RWD) vehicles, check the wheel bearing for a spalled cup and spalled/damaged rollers. Install a new wheel bearing if any of these concerns are detected. On four wheel drive (4WD) vehicles, check the wheel bearing for rotating smoothness and end play. Chuckle Chuckle that occurs on the coast driving phase is usually caused by excessive clearance between the differential gear hub and the differential case bore. Damage to a gear tooth on the coast side can cause a noise identical to a chuckle. A very small tooth nick or ridge on the edge of a tooth can cause the noise. Clean the gear tooth nick or ridge with a small grinding wheel. If the damaged area is larger than 3.2 mm (1/8 inch), install a new gearset. To check the ring gear and pinion, remove as much lubricant as possible from the gears with clean solvent. Wipe the gears dry or blow them dry with compressed air. Look for scored or damaged teeth. Also look for cracks or other damage. If either gear is scored or damaged badly, a new ring gear and pinion must be installed. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Testing and Inspection > Driveline System > Page 1874 If metal has broken loose, the axle housing must be cleaned to remove particles that will cause damage. At this time, any other damaged parts in the axle housing must also be installed new. Knock Knock, which can occur in all driving phases, has several causes including damaged teeth or gearset. 1. NOTE: Measure the end play with a Dial Indicator with Bracketry and not by feel. Knock is also caused by excessive end play in the axle shafts. Up to 0.762 mm (0.030 inch) is allowed in semi-float axles. The frequency of the knock will be less because the axle shaft speed is slower than the driveshaft. Clunk Clunk is a metallic noise heard when the automatic transmission is engaged in REVERSE or DRIVE. The noise can also occur when throttle is applied or released. It is caused by backlash somewhere in the driveline or loose suspension components; it is felt or heard in the axle. Additionally, clunk may be heard upon initial drive-away. This occurs as engine torque shifts vehicle weight, forcing changes in driveline angles which prevent the driveshaft slip-yoke from sliding on the output shaft. To correct this condition, lubricate the slip-yoke splines. Bearing Rumble Bearing rumble sounds like marbles being tumbled. This condition is usually caused by a worn/damaged wheel bearing. The lower pitch is because the wheel bearing turns at only about 1/3 of the driveshaft speed. Wheel bearing noise also may be high-pitched, similar to gear noise, but will be evident in all 4 driving modes. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Testing and Inspection > Driveline System > Page 1875 Wheel Hub: Testing and Inspection Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear Inspection and Verification Special Tool(s) Material The technician should have a thorough knowledge of driveline system operation and accepted general driveline guidelines to detect any problems. A gear driven unit will produce a certain amount of noise. Some noise is acceptable and audible at certain speeds or under various driving conditions. Certain conditions, such as road conditions and weather, will amplify normal vehicle noise. Certain rear axle and driveline concern symptoms are also common to the engine, transmission, rear wheel bearings and tire. For this reason, be sure the cause of the concern is in the axle before repairing or installing any axle components. This is a guide to diagnose a driveline concern: ^ Verify and document the customer concern. ^ Carry out a preliminary investigation. ^ Road test the vehicle. ^ Find the cause of the problem. ^ Inspect the components. 1. Verify and document the customer concern. 1 When was it first noticed? 2 Did it appear suddenly or gradually? 3 Did anything unusual occur that would coincide with it or precede it? 4 Has the driveline system been repaired before or new components installed? ^ Check the vehicle service record. Note any repairs other than driveline, such as brakes or suspension. 5 Are there any special conditions that will affect the concern or will alter the concern? For example, ^ road speed. ^ type of road. ^ drive mode. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Testing and Inspection > Driveline System > Page 1876 ^ temperature. ^ vehicle loaded or unloaded. 6 Is the condition constant or intermittent? Can the concern be duplicated at any time? 7 Check for TSBs. 2. NOTE: If the inspection reveals an obvious concern, repair the vehicle. Do a preliminary investigation. Visually inspect for obvious signs of damage. 1 Inspect the driveshaft: ^ for build up of any foreign material. ^ for damage, such as a bent tube or missing weights. ^ U-joints, CV joints or flex couplers for wear or damage. 2 Inspect the axle: ^ for signs of leakage at the drain or fill plug, differential seal, vent or halfshaft seals. a plugged vent or vent tube will cause a leak. ^ for damage, such as cracks, bent halfshafts or dented rear cover. ^ for missing fasteners. 3 Inspect other suspect components/systems: ^ inspect the suspension for broken springs, damaged shock absorbers and worn suspension bushings. ^ inspect the rear brake components - lines, cables and calipers. ^ inspect the tires; are they in good condition and do they match? 3. NOTE: A road test is necessary for any customer concern of noise or vibration. Road test the vehicle. 1 During the road test, use these driving methods to diagnose the problem. Is the concern most noticeable: ^ from a stop? ^ on shifts from REVERSE to DRIVE? ^ on turns? sweeping type turn. - tight turn (to the stop). ^ in DRIVE? accelerating the vehicle, definite throttle depression, applying engine torque. ^ in CRUISE? - maintaining a constant speed with the throttle applied. ^ in COAST? decelerating with the throttle closed. 2 Record when the concern occurs. Write down the kph (mph) range at which the noise/vibration occurs. 4. Find the cause of the problem. 1 Compare the inspection and road test results with the chart. 2 Use this diagnostic routine chart to identify the probable cause and know what corrective actions should be taken to repair the component/vehicle and to prevent a reoccurrence. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Testing and Inspection > Driveline System > Page 1877 Diagnostic Routine Chart 5. NOTE: If the conclusion of the road test points to an axle assembly section (ring and pinion or differential case) concern, carry out a visual inspection of the rear axle. Inspect the axle components. 1 Remove the axle assembly. 2 Remove the differential housing cover. Drain the axle lubricant through a white cloth. Check the fluid for: ^ any foreign material. ^ metal particles. ^ burnt odor. 3 NOTE: When inspecting the axle, do not clean the components immediately. Cleaning may remove diagnostic evidence. Inspect the axle components. ^ Look for: loose fasteners. - notches or visible steps or grooves created by wear. - pitting or cracking along gear contact lines. - scuffing or deformations. - discolorations. - nicks or ridges on gear teeth. ^ Clean the axle components for inspection. Remove as much lubricant as possible with clean solvent. Wipe the components or blow them dry with compressed air. ^ Re-inspect for: Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Testing and Inspection > Driveline System > Page 1878 - loose fasteners. - notches or visible steps or grooves created by wear. - pitting or cracking along gear contact lines. - scuffing or deformations. - discolorations. - nicks or ridges on gear teeth. ^ Check backlash and carry out a ring and pinion pattern test. See: Transmission and Drivetrain/Differential Assembly/Testing and Inspection/Component Tests and General Diagnostics/Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear/Checking Tooth Contact Pattern and Condition of The Ring and Pinion Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Front Wheel Hub: Service and Repair Front Wheel Bearing and Wheel Hub Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number or an equivalent part must be installed, if installation is necessary. Do not use a part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose can occur. Remove the bolts and position the caliper, pads and anchor plate assembly aside. ^ Discard the bolts. ^ Support the caliper and anchor plate assembly using mechanic's wire. ^ To install, tighten to 165 Nm (122 ft. lbs.) 3. Remove the brake disc. 4. CAUTION: Inspect and if necessary, clean area around wheel speed sensor before removing it from the wheel bearing and hub. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Front > Page 1881 Remove the wheel speed sensor bolt and disconnect the wheel speed sensor from the wheel bearing and hub assembly. ^ To install, tighten to 18 Nm (13 ft. lbs.) 5. Remove the 3 bolts and the wheel bearing and hub assembly. ^ Discard the bolts. ^ To install, tighten to 122 Nm (90 ft. lbs.) 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Front > Page 1882 Wheel Hub: Service and Repair Rear Wheel Bearing and Wheel Hub Special Tool(s) Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Remove the wheel knuckle. 2. Remove the 3 brake disc shield bolts. ^ To install, tighten to 8 Nm (71 inch lbs.) 3. Using the special tool and a suitable press, remove the wheel hub. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Front > Page 1883 4. Remove the snap ring. 5. Using a suitable press and adapters, remove the wheel bearing. 6. To install, reverse the removal procedure. 7. Install the wheel knuckle. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel Lug Nuts .......................................................................................................................................................... 135 Nm (100 ft. lbs.) in a star pattern Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front Wheel Studs Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose can occur. Remove the bolts and position the caliper, pads and anchor plate assembly aside. ^ Support the caliper and anchor plate assembly using mechanic's wire. ^ To install, tighten to 200 Nm (148 ft. lbs.) 3. Remove the brake disc. 4. Using the special tool, remove the wheel stud. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 1889 Installation 1. CAUTION: Do not use power tools to install the wheel stud. The serrations on the stud can be stripped. NOTE: Do not use the wheel nut that came with the vehicle. Install washers and a new wheel nut on the wheel stud and tighten the nut until the stud seats against the flange. ^ Discard the wheel nut and washers. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 1890 Wheel Fastener: Service and Repair Rear Wheel Studs Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 1891 Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. CAUTION: Orientation of the suspension fasteners is important. Make sure the fasteners are installed in the same direction as they were in when removed. 1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. CAUTION: Care must be used when servicing rear brake components without disconnecting the parking brake cable from the brake caliper lever. Carefully position the caliper aside using a suitable support or damage to the parking brake cable end fittings can occur. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose can occur. Remove the bolts and position the brake caliper aside. ^ Support the caliper using mechanic's wire. 3. Remove the brake disc. 4. Remove the parking brake shoe adjuster spring and adjuster. 5. CAUTION: The brake shield has an access hole knockout that must be removed to allow for the removal of the wheel stud. Using a suitable punch, remove the access hole cover from the brake shield. 6. NOTE: Make sure that the wheel stud is aligned with the recessed area of the wheel knuckle. Using the special tool, press the wheel stud until it makes contact with the edge of the wheel knuckle. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 1892 7. Route the wheel stud through the access hole and discard the wheel stud. Installation 1. Position the new wheel stud aligning the serrations in the wheel hub made by the original wheel stud. 2. CAUTION: Do not use power tools to install the wheel stud. The serrations on the stud can be stripped. NOTE: Do not use the wheel nut that came with the vehicle. Place flat washers over the outside end of the wheel stud and thread a standard wheel nut with the flat side against the washers. Tighten the wheel nut until the wheel stud seats against the back side of the wheel extension. ^ Discard the wheel nut and washers. 3. CAUTION: A plug must be installed in place of the knockout to prevent contamination to the parking brake shoe assemblies. Install a plug into the access hole on the brake shield. 4. Install the parking brake shoe adjuster and spring. 5. Install the brake disc. 6. Position the brake caliper and install the bolts. ^ Tighten to 32 Nm (24 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation JACKING WARNING: - 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 correctly located to prevent the vehicle from falling. CAUTION: - A wheel chock should be used to prevent the vehicle from rolling and falling off the jack. - Position the jack to avoid contact with the fuel tank. The following offers general guidelines for vehicle jacking. Additionally, jack manufacturers offer their own operating precautions. Be sure to read and understand operating instructions for the jacking equipment before use. Jacking Points NOTE: Place a wheel chock diagonally opposite of the wheel to be raised. The front jacking points are indicated by a cut-out in the frame, located behind the front tire and wheel. CAUTION: Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and adjoining differential housing Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation > Page 1896 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. The rear jacking points are indicated by a cut-out in the frame in front of the rear tire and wheel. LIFTING Lifting Points 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. - 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. - Position the hoist adapters to avoid contact with the fuel tank. - To avoid damage to the suspension, do not position the hoist adapters on the rear trailing arm brackets. NOTE: Explorer shown, Explorer Sport Trac similar. The following offers general guidelines for vehicle lifting. Additionally, hoist manufacturers offer their own operating precautions. Be sure to read and understand operating instructions for the lifting equipment before use. Position the hoist directly under the frame rails. Position the hoist directly under the frame rails. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 C1451 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 > Page 1904 C1452 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1905 Variable Valve Timing Actuator: Description and Operation VARIABLE CAMSHAFT TIMING (VCT) SYSTEM Overview The VCT enables rotation of the camshaft(s) relative to the crankshaft rotation as a function of engine operating conditions. There are 4 types of VCT systems. Exhaust phase shifting (EPS) system - the exhaust cam is the active cam being retarded. - Intake phase shifting (IPS) system - the intake cam is the active cam being advanced. - Dual equal phase shifting (DEPS) system - both intake and exhaust cams are phase shifted and equally advanced or retarded. - Dual independent phase shifting (DIPS) system - where both the intake and exhaust cams are shifted independently. All systems have 4 operational modes: idle, part throttle, wide open throttle (WOT), and default mode. At idle and low engine speeds with closed throttle, the powertrain control module (PCM) determines the phase angle based on air flow, engine oil temperature and engine coolant temperature. At part and wide open throttle the PCM determines the phase angle based on engine RPM, load, and throttle position. VCT systems provide reduced emissions and enhanced engine power, fuel economy and idle quality. IPS systems also have the added benefit of improved torque. In addition, some VCT system applications can eliminate the need for an external exhaust gas recirculation (EGR) system. The elimination of the EGR system is accomplished by controlling the overlap time between the intake valve opening and exhaust valve closing. Currently, both the IPS and DEPS systems are used. Variable Camshaft Timing (VCT) System VCT System The VCT system consists of an electric hydraulic positioning control solenoid, a camshaft position (CMP) sensor, and a trigger wheel. The CMP trigger wheel has a number of equally spaced teeth equal to the number (n) of cylinders on a bank plus one extra tooth (n+1). Four cylinder and V8 engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1 tooth trigger wheel. The extra tooth placed between the equally spaced teeth represents the CMP signal for that bank. A crankshaft position sensor (CKP) provides the PCM with crankshaft positioning information in 10 degree increments. 1. The PCM receives input signals from the intake air temperature (IAT) sensor, engine coolant temperature (ECT) sensor, engine oil temperature (EOT) sensor, CMP, throttle position (TP) sensor, mass air flow (MAF) sensor, and CKP to determine the operating conditions of the engine. At idle and low engine speeds with closed throttle, the PCM controls the camshaft position based on ECT, EOT, IAT, and MAF. During part and wide open throttle, the camshaft position is determined by engine RPM, load and throttle position. The VCT system does not operate until the engine is at normal operating temperature. 2. The VCT system is enabled by the PCM when the correct conditions are met. 3. The CKP signal is used as a reference for CMP positioning. 4. The VCT solenoid valve is an integral part of the VCT system. The solenoid valve controls the flow of engine oil in the VCT actuator assembly. As the PCM controls the duty cycle of the solenoid valve, oil pressure/flow advances or retards the cam timing. Duty cycles near 0% or 100% represent rapid movement of the camshaft. Retaining a fixed camshaft position is accomplished by dithering (oscillating) the solenoid valve duty cycle. The PCM calculates and determines the desired camshaft position. It continually updates the VCT solenoid duty cycle until the desired position is achieved. A difference between the desired and actual camshaft position represents a position error in the PCM VCT control loop. The PCM disables the VCT and places the camshaft in a default position if a concern is detected. A related DTC is also set when the concern is detected. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1906 5. When the VCT solenoid is energized, engine oil is allowed to flow to the VCT actuator assembly which advances or retards the camshaft timing. One half of the VCT actuator is coupled to the camshaft and the other half is connected to the timing chain. Oil chambers between the 2 halves couple the camshaft to the timing chain. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the camshaft to rotate in either an advance or retard position depending on the oil flow. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Service and Repair Variable Valve Timing Solenoid: Service and Repair VARIABLE CAMSHAFT TIMING (VCT) OIL CONTROL SOLENOID Removal and Installation 1. Remove the valve cover. 2. Remove the bolt and the VCT oil control solenoid. - To install, tighten to 5 Nm (44 lb-in). 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 at least 75% of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Compression Pressure Limit Chart Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1913 Compression Check: Testing and Inspection Compression Test - Compression Gauge Check 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 5 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 at least 75% of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Compression Pressure Limit Chart If one or more cylinders read low, squirt approximately one tablespoon of engine oil 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. 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If 2 adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1914 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 at least 75% of the highest reading. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Tighten the bolts in the sequence shown in 2 stages. Stage 1: Tighten to .............................................................................................................................. ........................................ 6 Nm (53 inch lbs.). Stage 2: Tighten to ..................................................... ................................................................................................................... 16 Nm (12 ft. lbs.). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Bearing Journal Clearance Camshaft: Service and Repair Camshaft Bearing Journal Clearance Camshaft Bearing Journal Clearance NOTE: The camshaft journals must meet specifications before checking camshaft journal clearance. 1. Remove the camshaft bearing cap and lay Plastigage across the surface. 2. NOTE: Do not turn the camshaft while carrying out this procedure. Position the camshaft bearing cap and install the bolts. 3. Use Plastigage to verify the camshaft journal clearance. ^ If out of specification, install new components as necessary. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Bearing Journal Clearance > Page 1923 Camshaft: Service and Repair Camshaft Surface Inspection Camshaft Surface Inspection 1. Inspect camshaft lobes for pitting or damage in the contact area. Minor pitting is acceptable outside the contact area. ^ If excessive pitting or damage is present, install new components as necessary. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Bearing Journal Clearance > Page 1924 Camshaft: Service and Repair Camshafts Camshafts Special Tools Material Removal Both sides 1. Remove the camshaft roller followers. 2. Remove the nut and position the wiring harness bracket aside. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Bearing Journal Clearance > Page 1925 3. NOTE: You must carry out the RH and LH camshaft timing procedure when either camshaft is serviced. Rotate the crankshaft clockwise to position the No. 1 cylinder at top dead center (TDC). 4. CAUTION: Do not rotate the engine counterclockwise. Rotating the engine counterclockwise will result in incorrect timing of the engine. NOTE: The special tool must be installed on the damper and should contact the engine block. This positions the piston at TDC. Install the special tool. RH side 5. Remove the RH hydraulic timing chain tensioner. 6. Install the special tools on the rear of the RH cylinder head and tighten the top 2 clamp bolts to 10 Nm (89 inch lbs.). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Bearing Journal Clearance > Page 1926 7. CAUTION: The RH camshaft sprocket is a LH-threaded bolt. Turning the bolt in the wrong direction can damage the engine. Using the special tool and the Camshaft Sprocket Nut Socket, loosen the camshaft sprocket bolt. 8. Remove the bolt and position the camshaft sprocket aside. LH side 9. Remove the LH hydraulic timing chain tensioner. 10. Rotate the accessory drive belt tensioner counterclockwise and detach the accessory drive belt from the A/C compressor and power steering pump pulleys. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Bearing Journal Clearance > Page 1927 11. Remove the bolts and position the A/C compressor and power steering pump bracket aside. 12. Install the special tools on the front of the LH camshaft and tighten the 2 top clamp bolts to 10 Nm (89 inch lbs.). 13. Loosen the bolt. 14. Remove the bolt and position the camshaft sprocket aside. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Bearing Journal Clearance > Page 1928 Both sides 15. NOTE: Mark the position of the camshaft bearing caps so they can be installed in their original positions. Remove the bolts in the sequence shown and remove the camshaft bearing caps and, if equipped, the oil supply tube. 16. Remove the camshaft. Installation NOTE: Lubricate the camshaft journal bearing surfaces on the cylinder head, the camshaft journals and the camshaft bearing caps with clean engine oil. Both sides 1. Install the camshaft. 2. NOTE: The camshaft bearing caps must be installed in their original positions. NOTE: After installing the bolts, check the camshaft for free rotation. Position the oil supply tube, if equipped, the camshaft bearing caps and the bolts. ^ Tighten the bolts in the sequence shown in 2 stages. Stage 1: Tighten to 6 Nm (53 inch lbs.). - Stage 2: Tighten to 16 Nm (12 ft. lbs.). RH side 3. CAUTION: The camshaft gear must turn freely on the camshaft. DO NOT tighten the bolt at this time. Tightening the bolt can result in Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Bearing Journal Clearance > Page 1929 incorrect engine timing. Install the camshaft sprocket and loosely install the bolt. LH side 4. CAUTION: The camshaft gear must turn freely on the camshaft. DO NOT tighten the bolt at this time. Tightening the bolt can result in incorrect engine timing. Install the camshaft sprocket and loosely install the bolt. Both sides 5. Time the camshafts. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Bearing Journal Clearance > Page 1930 Camshaft: Service and Repair Camshaft Bearing Journal Diameter Camshaft Bearing Journal Diameter 1. Measure each camshaft journal diameter in 2 directions. ^ If out of specification, install new components as necessary. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Bearing Journal Clearance > Page 1931 Camshaft: Service and Repair Camshaft Bearing Journal Clearance Camshaft Bearing Journal Clearance NOTE: The camshaft journals must meet specifications before checking camshaft journal clearance. 1. Remove the camshaft bearing cap and lay Plastigage across the surface. 2. NOTE: Do not turn the camshaft while carrying out this procedure. Position the camshaft bearing cap and install the bolts. 3. Use Plastigage to verify the camshaft journal clearance. ^ If out of specification, install new components as necessary. Camshaft Surface Inspection Camshaft Surface Inspection 1. Inspect camshaft lobes for pitting or damage in the contact area. Minor pitting is acceptable outside the contact area. ^ If excessive pitting or damage is present, install new components as necessary. Camshafts Camshafts Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Bearing Journal Clearance > Page 1932 Special Tools Material Removal Both sides 1. Remove the camshaft roller followers. 2. Remove the nut and position the wiring harness bracket aside. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Bearing Journal Clearance > Page 1933 3. NOTE: You must carry out the RH and LH camshaft timing procedure when either camshaft is serviced. Rotate the crankshaft clockwise to position the No. 1 cylinder at top dead center (TDC). 4. CAUTION: Do not rotate the engine counterclockwise. Rotating the engine counterclockwise will result in incorrect timing of the engine. NOTE: The special tool must be installed on the damper and should contact the engine block. This positions the piston at TDC. Install the special tool. RH side 5. Remove the RH hydraulic timing chain tensioner. 6. Install the special tools on the rear of the RH cylinder head and tighten the top 2 clamp bolts to 10 Nm (89 inch lbs.). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Bearing Journal Clearance > Page 1934 7. CAUTION: The RH camshaft sprocket is a LH-threaded bolt. Turning the bolt in the wrong direction can damage the engine. Using the special tool and the Camshaft Sprocket Nut Socket, loosen the camshaft sprocket bolt. 8. Remove the bolt and position the camshaft sprocket aside. LH side 9. Remove the LH hydraulic timing chain tensioner. 10. Rotate the accessory drive belt tensioner counterclockwise and detach the accessory drive belt from the A/C compressor and power steering pump pulleys. 11. Remove the bolts and position the A/C compressor and power steering pump bracket aside. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Bearing Journal Clearance > Page 1935 12. Install the special tools on the front of the LH camshaft and tighten the 2 top clamp bolts to 10 Nm (89 inch lbs.). 13. Loosen the bolt. 14. Remove the bolt and position the camshaft sprocket aside. Both sides 15. NOTE: Mark the position of the camshaft bearing caps so they can be installed in their original positions. Remove the bolts in the sequence shown and remove the camshaft bearing caps and, if equipped, the oil supply tube. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Bearing Journal Clearance > Page 1936 16. Remove the camshaft. Installation NOTE: Lubricate the camshaft journal bearing surfaces on the cylinder head, the camshaft journals and the camshaft bearing caps with clean engine oil. Both sides 1. Install the camshaft. 2. NOTE: The camshaft bearing caps must be installed in their original positions. NOTE: After installing the bolts, check the camshaft for free rotation. Position the oil supply tube, if equipped, the camshaft bearing caps and the bolts. ^ Tighten the bolts in the sequence shown in 2 stages. Stage 1: Tighten to 6 Nm (53 inch lbs.). - Stage 2: Tighten to 16 Nm (12 ft. lbs.). RH side 3. CAUTION: The camshaft gear must turn freely on the camshaft. DO NOT tighten the bolt at this time. Tightening the bolt can result in incorrect engine timing. Install the camshaft sprocket and loosely install the bolt. LH side Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Bearing Journal Clearance > Page 1937 4. CAUTION: The camshaft gear must turn freely on the camshaft. DO NOT tighten the bolt at this time. Tightening the bolt can result in incorrect engine timing. Install the camshaft sprocket and loosely install the bolt. Both sides 5. Time the camshafts. Camshaft Bearing Journal Diameter Camshaft Bearing Journal Diameter 1. Measure each camshaft journal diameter in 2 directions. ^ If out of specification, install new components as necessary. Camshaft End Play Camshaft End Play Special Tools 1. Remove the roller followers. 2. Use the special tool to measure camshaft end play. 3. Position the camshaft to the rear of the cylinder head. 4. Zero the indicator. 5. Move the camshaft to the front of the cylinder head. Note and record the camshaft end play. ^ If camshaft end play exceeds specifications, install new camshaft and recheck end play. ^ If camshaft end play exceeds specification after camshaft installation, install a new cylinder head. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Bearing Journal Clearance > Page 1938 Camshaft Lobe Lift Camshaft Lobe Lift Special Tools 1. Use the special tool to measure camshaft intake/exhaust lobe lift. ^ Rotate the camshaft and subtract the lowest indicator reading from the highest indicator reading to figure the camshaft lobe lift. Camshaft Runout Camshaft Runout Special Tool(s) 1. NOTE: Camshaft journals must be within specifications before checking runout. Use the special tool to measure the camshaft runout. ^ Rotate the camshaft and subtract the lowest indicator reading from the highest indicator reading. ^ If out of specification, install new components as necessary. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Bearing Journal Clearance > Page 1939 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Testing and Inspection Lifter / Lash Adjuster: Testing and Inspection Valve Tappet Inspection Push rod engines 1. Inspect the hydraulic valve tappet and roller for damage. If any damage is found, inspect the camshaft lobes and valves for damage. OHC engines Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Testing and Inspection > Page 1943 Lifter / Lash Adjuster: Service and Repair Hydraulic Lash Adjuster Material Removal and Installation 1. Remove the camshaft roller followers. 2. NOTE: Mark each hydraulic lash adjuster to make sure it is returned to its original position. Remove the hydraulic lash adjusters. 3. NOTE: The hydraulic lash adjusters must be installed in their original positions. NOTE: Lubricate the hydraulic lash adjusters with clean engine oil. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Camshaft Roller Follower Special Tools Material Removal and Installation 1. Remove the LH and RH valve covers. 2. Remove the fuel rail. 3. Remove the cooling fan. 4. Rotate the crankshaft until the camshaft for the cylinder being serviced is at base circle. 5. NOTE: Mark each camshaft roller follower to make sure it is returned to its original position. Using the special tool, remove the camshaft roller followers. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Page 1947 6. NOTE: The camshaft roller followers must be installed in their original positions. NOTE: Lubricate the camshaft roller followers with clean engine oil. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 C1451 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 > Page 1952 C1452 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1953 Variable Valve Timing Actuator: Description and Operation VARIABLE CAMSHAFT TIMING (VCT) SYSTEM Overview The VCT enables rotation of the camshaft(s) relative to the crankshaft rotation as a function of engine operating conditions. There are 4 types of VCT systems. Exhaust phase shifting (EPS) system - the exhaust cam is the active cam being retarded. - Intake phase shifting (IPS) system - the intake cam is the active cam being advanced. - Dual equal phase shifting (DEPS) system - both intake and exhaust cams are phase shifted and equally advanced or retarded. - Dual independent phase shifting (DIPS) system - where both the intake and exhaust cams are shifted independently. All systems have 4 operational modes: idle, part throttle, wide open throttle (WOT), and default mode. At idle and low engine speeds with closed throttle, the powertrain control module (PCM) determines the phase angle based on air flow, engine oil temperature and engine coolant temperature. At part and wide open throttle the PCM determines the phase angle based on engine RPM, load, and throttle position. VCT systems provide reduced emissions and enhanced engine power, fuel economy and idle quality. IPS systems also have the added benefit of improved torque. In addition, some VCT system applications can eliminate the need for an external exhaust gas recirculation (EGR) system. The elimination of the EGR system is accomplished by controlling the overlap time between the intake valve opening and exhaust valve closing. Currently, both the IPS and DEPS systems are used. Variable Camshaft Timing (VCT) System VCT System The VCT system consists of an electric hydraulic positioning control solenoid, a camshaft position (CMP) sensor, and a trigger wheel. The CMP trigger wheel has a number of equally spaced teeth equal to the number (n) of cylinders on a bank plus one extra tooth (n+1). Four cylinder and V8 engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1 tooth trigger wheel. The extra tooth placed between the equally spaced teeth represents the CMP signal for that bank. A crankshaft position sensor (CKP) provides the PCM with crankshaft positioning information in 10 degree increments. 1. The PCM receives input signals from the intake air temperature (IAT) sensor, engine coolant temperature (ECT) sensor, engine oil temperature (EOT) sensor, CMP, throttle position (TP) sensor, mass air flow (MAF) sensor, and CKP to determine the operating conditions of the engine. At idle and low engine speeds with closed throttle, the PCM controls the camshaft position based on ECT, EOT, IAT, and MAF. During part and wide open throttle, the camshaft position is determined by engine RPM, load and throttle position. The VCT system does not operate until the engine is at normal operating temperature. 2. The VCT system is enabled by the PCM when the correct conditions are met. 3. The CKP signal is used as a reference for CMP positioning. 4. The VCT solenoid valve is an integral part of the VCT system. The solenoid valve controls the flow of engine oil in the VCT actuator assembly. As the PCM controls the duty cycle of the solenoid valve, oil pressure/flow advances or retards the cam timing. Duty cycles near 0% or 100% represent rapid movement of the camshaft. Retaining a fixed camshaft position is accomplished by dithering (oscillating) the solenoid valve duty cycle. The PCM calculates and determines the desired camshaft position. It continually updates the VCT solenoid duty cycle until the desired position is achieved. A difference between the desired and actual camshaft position represents a position error in the PCM VCT control loop. The PCM disables the VCT and places the camshaft in a default position if a concern is detected. A related DTC is also set when the concern is detected. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Diagrams > Page 1954 5. When the VCT solenoid is energized, engine oil is allowed to flow to the VCT actuator assembly which advances or retards the camshaft timing. One half of the VCT actuator is coupled to the camshaft and the other half is connected to the timing chain. Oil chambers between the 2 halves couple the camshaft to the timing chain. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the camshaft to rotate in either an advance or retard position depending on the oil flow. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Connecting rod bearing-to-crankshaft clearance ....................................................................................................... 0.008-0.061 mm (0.0003-0.0024 inch) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications Connecting rod pin bore diameter ............................................................................................................................. 23.958-23.976 mm (0.943-0.944 inch) Connecting rod length (center-to-center) .............................................................................................................. 145.965-146.035 mm (5.747-5.749 inch) Connecting rod maximum allowed bend ................................................................................................ 0.013 mm (0.0005 inch) per 25.4 mm (1.000 inch) Connecting rod maximum allowed twist ................................................................................................ 0.038 mm (0.0015 inch) per 25.4 mm (1.000 inch) Connecting rod bearing bore diameter ........................................................................................................... 56.82 mm - 56.84 mm (2.237 in - 2.238 inch) Connecting rod side clearance ................................................................................................................................... 0.092-0.268 mm (0.0036-0.0106 inch) Connecting Rod Bolts Stage 1: Tighten to .............................................................................................................................. ................................................ 20 Nm (15 ft. lbs.). Stage 2: Tighten an .............................................. ........................................................................................................................... additional 90 degrees. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1962 Connecting Rod: Testing and Inspection Bearing Inspection 1. Inspect bearings for the following defects. Possible causes are shown: 1 Cratering - fatigue failure. 2 Spot polishing - incorrect seating. 3 Imbedded dirt engine oil. 4 Scratching - dirty engine oil. 5 Base exposed - poor lubrication. 6 Both edges worn - journal damaged. 7 One edge worn - journal tapered or bearing not seated. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Connecting Rod Bearing Journal-to-Bearing Clearance Connecting Rod: Service and Repair Connecting Rod Bearing Journal-to-Bearing Clearance Connecting Rod Bearing Journal-to-Bearing Clearance NOTE: The crankshaft connecting rod journals must be within specifications to check the connecting rod bearing journal clearance. 1. Remove the connecting rod bearing cap. 2. Position a piece of Plastigage across the bearing surface. 3. NOTE: Do not turn the crankshaft during this step. Install and tighten to specifications, then remove the connecting rod bearing cap. 4. Measure the Plastigage to get the connecting rod bearing journal clearance. The Plastigage should be smooth and flat. A changing width indicates a tapered or damaged connecting rod or connecting rod bearing. ^ If out of specification, install new components as necessary. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Connecting Rod Bearing Journal-to-Bearing Clearance > Page 1965 Connecting Rod: Service and Repair Connecting Rod Bend Connecting Rod Bend 1. Measure the connecting rod bend on a suitable alignment fixture. Follow the instructions of the fixture manufacturer. Verify the bend measurement is within specification. ^ If out of specification, install new components as necessary. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Connecting Rod Bearing Journal-to-Bearing Clearance > Page 1966 Connecting Rod: Service and Repair Connecting Rod Bushing Diameter Connecting Rod Bushing Diameter 1. Use a telescoping gauge to determine the inner diameter of the connecting rod bushing, if equipped. 2. Measure the telescoping gauge with a micrometer. Verify the diameter is within specification. ^ If out of specification, install new components as necessary. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Connecting Rod Bearing Journal-to-Bearing Clearance > Page 1967 Connecting Rod: Service and Repair Connecting Rod Cleaning Connecting Rod Cleaning CAUTION: Do not use a caustic cleaning solution or damage to connecting rods can occur. 1. NOTE: The connecting rod large end is a matched set. The connecting rod cap must be installed on the original connecting rod in the original position. Do not reverse the cap. Parts are not interchangeable. Mark and separate the parts and clean with solvent. Clean the oil passages. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Connecting Rod Bearing Journal-to-Bearing Clearance > Page 1968 Connecting Rod: Service and Repair Connecting Rod Bearing Journal-to-Bearing Clearance Connecting Rod Bearing Journal-to-Bearing Clearance NOTE: The crankshaft connecting rod journals must be within specifications to check the connecting rod bearing journal clearance. 1. Remove the connecting rod bearing cap. 2. Position a piece of Plastigage across the bearing surface. 3. NOTE: Do not turn the crankshaft during this step. Install and tighten to specifications, then remove the connecting rod bearing cap. 4. Measure the Plastigage to get the connecting rod bearing journal clearance. The Plastigage should be smooth and flat. A changing width indicates a tapered or damaged connecting rod or connecting rod bearing. ^ If out of specification, install new components as necessary. Connecting Rod Bend Connecting Rod Bend 1. Measure the connecting rod bend on a suitable alignment fixture. Follow the instructions of the fixture manufacturer. Verify the bend measurement is within specification. ^ If out of specification, install new components as necessary. Connecting Rod Bushing Diameter Connecting Rod Bushing Diameter 1. Use a telescoping gauge to determine the inner diameter of the connecting rod bushing, if equipped. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Connecting Rod Bearing Journal-to-Bearing Clearance > Page 1969 2. Measure the telescoping gauge with a micrometer. Verify the diameter is within specification. ^ If out of specification, install new components as necessary. Connecting Rod Cleaning Connecting Rod Cleaning CAUTION: Do not use a caustic cleaning solution or damage to connecting rods can occur. 1. NOTE: The connecting rod large end is a matched set. The connecting rod cap must be installed on the original connecting rod in the original position. Do not reverse the cap. Parts are not interchangeable. Mark and separate the parts and clean with solvent. Clean the oil passages. Connecting Rod Large End Bore Connecting Rod Large End Bore 1. Tighten the bolts to specification, then measure the bore in 2 directions. The difference is the connecting rod bore out-of-round. Verify the out-of-round is within specification. ^ If out of specification, install new components as necessary. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Connecting Rod Bearing Journal-to-Bearing Clearance > Page 1970 Connecting Rod Twist Connecting Rod Twist 1. Measure the connecting rod twist on a suitable alignment fixture. Follow the instructions of the fixture manufacturer. Verify the measurement is within specification. ^ If out of specification, install new components as necessary. Piston Wrist Pin Side Clearance Piston Wrist Pin Side Clearance 1. Measure the clearance between the connecting rod and the piston. Verify the measurement is within specification. ^ If out of specification, install new components as necessary. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications Main Bearings Clearance to crankshaft ......................................................................................................................................... 0.021-0.039 mm (0.0008-0.0015 inch) Clearance to crankshaft allowable ........................................................................................................................... 0.013-0.048 mm (0.0005-0.002 inch) Bearing wall thickness ............................................................................................................................................... 1.8-1.806 mm (0.0709-0.0711 inch) Main bearing cap bolts ........................................................................................................................ ..................................................... 97 Nm (72 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1974 Crankshaft Main Bearing: Testing and Inspection Bearing Inspection 1. Inspect bearings for the following defects. Possible causes are shown: 1 Cratering - fatigue failure. 2 Spot polishing - incorrect seating. 3 Imbedded dirt engine oil. 4 Scratching - dirty engine oil. 5 Base exposed - poor lubrication. 6 Both edges worn - journal damaged. 7 One edge worn - journal tapered or bearing not seated. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Main bearing journal diameter ...................................................................................................................................... 56.980-57.0 mm (2.243-2.244 inch) Main bearing journal maximum taper .............................................................................................................................................. 0.008 mm (0.0003 inch) Main bearing journal maximum out-of-round .................................................................................................................................. 0.008 mm (0.0003 inch) Connecting rod journal diameter ..................................................................................................................................... 53.98-54.0 mm (2.125-2.126 inch) Connecting rod journal maximum taper ........................................................................................................................................... 0.008 mm (0.0003 inch) Connecting rod journal maximum out-of-round .............................................................................................................................. 0.008 mm (0.0003 inch) Crankshaft maximum end play ........................................................................................................................................ 0.05-0.32 mm (0.002-0.0126 inch) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crankshaft Main Bearing Journal Taper and Out-of-Round Crankshaft: Service and Repair Crankshaft Main Bearing Journal Taper and Out-of-Round Crankshaft Main Bearing Journal Taper and Out-of-Round 1. Measure each of the crankshaft main bearing journal diameters in at least 2 directions at each end of the main bearing journal. ^ If out of specification, install new components as necessary. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crankshaft Main Bearing Journal Taper and Out-of-Round > Page 1980 Crankshaft: Service and Repair Crankshaft Main Bearing Journal-to-Bearing Clearance Crankshaft Main Bearing Journal-to-Bearing Clearance NOTE: Crankshaft main bearing journals must be within specifications before checking journal clearance. 1. Remove the crankshaft main bearing caps and crankshaft main bearing. 2. Lay a piece of Plastigage across the face of each crankshaft main bearing surface. 3. NOTE: Do not turn the crankshaft while carrying out this procedure. Install and remove the crankshaft main bearing cap. 4. Verify the crankshaft journal clearance. ^ If out of specification, install new components as necessary. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crankshaft Main Bearing Journal Taper and Out-of-Round > Page 1981 Crankshaft: Service and Repair Crankshaft End Play Crankshaft End Play Special Tool(s) 1. Measure the crankshaft end play. Use the special tool to measure crankshaft end play. 2. Position the crankshaft to the rear of the cylinder block. 3. Zero the indicator. 4. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play. ^ If crankshaft end play exceeds specifications, install a new crankshaft thrust washer or crankshaft thrust main bearing. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crankshaft Main Bearing Journal Taper and Out-of-Round > Page 1982 Crankshaft: Service and Repair Crankshaft Runout Crankshaft Runout Special Tools 1. NOTE: Crankshaft main bearing journals must be within specifications before checking runout. Use the special tool to measure the crankshaft runout. ^ Rotate the crankshaft and subtract the lowest dial indicator reading from the highest dial indicator reading to figure the crankshaft runout. If it is out of specification, install new components as necessary. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crankshaft Main Bearing Journal Taper and Out-of-Round > Page 1983 Crankshaft: Service and Repair Crankshaft Main Bearing Journal Taper and Out-of-Round Crankshaft Main Bearing Journal Taper and Out-of-Round 1. Measure each of the crankshaft main bearing journal diameters in at least 2 directions at each end of the main bearing journal. ^ If out of specification, install new components as necessary. Crankshaft Main Bearing Journal-to-Bearing Clearance Crankshaft Main Bearing Journal-to-Bearing Clearance NOTE: Crankshaft main bearing journals must be within specifications before checking journal clearance. 1. Remove the crankshaft main bearing caps and crankshaft main bearing. 2. Lay a piece of Plastigage across the face of each crankshaft main bearing surface. 3. NOTE: Do not turn the crankshaft while carrying out this procedure. Install and remove the crankshaft main bearing cap. 4. Verify the crankshaft journal clearance. ^ If out of specification, install new components as necessary. Crankshaft End Play Crankshaft End Play Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crankshaft Main Bearing Journal Taper and Out-of-Round > Page 1984 Special Tool(s) 1. Measure the crankshaft end play. Use the special tool to measure crankshaft end play. 2. Position the crankshaft to the rear of the cylinder block. 3. Zero the indicator. 4. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play. ^ If crankshaft end play exceeds specifications, install a new crankshaft thrust washer or crankshaft thrust main bearing. Crankshaft Runout Crankshaft Runout Special Tools 1. NOTE: Crankshaft main bearing journals must be within specifications before checking runout. Use the special tool to measure the crankshaft runout. ^ Rotate the crankshaft and subtract the lowest dial indicator reading from the highest dial indicator reading to figure the crankshaft runout. If it is out of specification, install new components as necessary. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crankshaft Main Bearing Journal Taper and Out-of-Round > Page 1985 Crankshaft Main Bearing Journal Diameter Crankshaft Main Bearing Journal Diameter 1. Measure each of the crankshaft main bearing journal diameters in at least 2 directions. ^ If out of specification, install new components as necessary. Connecting Rod Bearing Journal Taper and Out-of-Round Connecting Rod Bearing Journal Taper and Out-of-Round 1. Measure the crankshaft connecting rod journal diameters in 2 directions perpendicular to one another at each end of the connecting rod journal. The difference in the measurements from one end to the other is the taper. Verify measurement is within the wear limit. ^ If out of specification, install new components as necessary. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair Engine Block Heater: Service and Repair Block Heater Material Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair 2. Drain the cooling system. 3. Disconnect the block heater power cable. 4. CAUTION: Do not loosen the block heater retaining screw more than necessary for removal. Loosen the screw and remove the block heater. ^ To install, tighten to 3 Nm (27 inch lbs.). 5. Clean and inspect the engine block mating surface. Lubricate the block heater seal and the cylinder block hole with clean engine coolant. 6. CAUTION: Make sure the power cable is routed and secured away from rotating or hot components or damage to the cable can occur. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Stage 1: Tighten to .............................................................................................................................. ................................................ 45 Nm (33 ft. lbs.). Stage 2: Tighten an .............................................. ........................................................................................................................... additional 85 degrees. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1992 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Pulley Special Tools General Equipment Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1993 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair 2. Remove the fan shroud. 3. Remove the accessory drive belt. 4. NOTE: This bolt is torque-to-yield and cannot be reused. Using the special tool to hold the crankshaft pulley, remove the bolt. 5. NOTE: If the pulley bolt is not installed, the tool will bottom out before the pulley is off. Install the crankshaft pulley bolt 2 to 3 turns. Using the special tools and the two 8-mm bolts, remove the crankshaft pulley. ^ Discard the crankshaft pulley bolt. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1994 Installation 1. Using the special tool, install the crankshaft pulley. 2. Using the special tool to hold the crankshaft pulley, install a new crankshaft pulley bolt. Tighten the bolt in 2 stages. ^ Stage 1: Tighten to 45 Nm (33 ft. lbs.). ^ Stage 2: Tighten an additional 85 degrees. 3. Install the accessory drive belt. 4. Install the fan shroud. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Piston diameter - coded standard ........................................................................................................................ 100.380-100.400 mm (3.952-3.9528 inch) Piston diameter - coded 0.5 ................................................................................................................................... 100.880-100.900 mm (3.971-3.972 inch) Piston diameter - coded 1.0 ................................................................................................................................... 101.390-101.400 mm (3.991-3.992 inch) Piston-to-cylinder bore clearance ................................................................................................................................ 0.030-0.050 mm (0.0012-0.002 inch) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures Piston: Procedures Piston Inspection Piston Inspection Special Tool(s) CAUTION: Do not use a caustic cleaning solution or a wire brush to clean the pistons or damage can occur. 1. Clean and inspect the (1) ring lands, (2) skirts, (3) pin bosses and the (4) tops of the pistons. If wear marks, scores or glazing is found on the piston skirt, check for a bent or twisted connecting rod. 2. Use the Piston Ring Groove Scraper to clean the piston ring grooves. ^ Make sure the oil ring holes are clean. Piston Pin to Bore Diameter Piston Pin to Bore Diameter 1. WARNING: Cover the end of the pin bore with a hand or shop rag when removing the retainer ring, since it has a tendency to spring out. Wear eye protection. Failure to follow instructions may result in personal injury. NOTE: Piston and piston pins are a matched set and should not be interchanged. Measure the piston pin bore diameter in 2 directions on each side. Verify the diameter is within specification. ^ If out of specification, install new components as necessary. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2000 Piston Diameter Piston Diameter 1. Measure the piston diameter 90 degrees from the piston pin and 42 mm (1.65 inch) down from the top of the piston at the point indicated. ^ If out of specification, install new components as necessary. Piston to Cylinder Bore Clearance Piston To Cylinder Bore Clearance 1. Subtract the piston diameter from the cylinder bore diameter to find the piston-to-cylinder bore clearance. Piston Selection Piston Selection NOTE: The cylinder bore must be within the specifications for taper and out-of-round before fitting a piston. 1. Select a piston size based on the cylinder bore. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2001 2. NOTE: For precision fit, new pistons are divided into 3 categories (grade sizes). A paint spot on the new pistons indicates the grade size. Choose the piston with the correct paint color after measuring the cylinder bore diameter. Choose the piston with the correct paint color. Piston Ring End Gap Piston Ring End Gap CAUTION: Use care when fitting piston rings to avoid possible damage to the piston ring or the cylinder bore. CAUTION: Piston rings should not be transferred from one piston to another. NOTE: Cylinder bore must be within specification for taper and out-of-round. 1. Use a piston without rings to push a piston ring in a cylinder to the bottom of ring travel. 2. Use a feeler gauge to measure the top piston ring end gap and the second piston ring end gap. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2002 Piston Ring-to-Groove Clearance Piston Ring-to-Groove Clearance 1. Inspect the piston for ring land damage or accelerated wear. 2. Measure the piston ring-to-groove clearance. ^ If out of specification, install new components as necessary. Piston Pin Diameter Piston Pin Diameter 1. Measure the piston pin diameter in 2 directions at the points shown. Verify the diameter is within specification. ^ If out of specification, install new components as necessary. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2003 Piston: Overhaul Piston Special Tools Material Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2004 Disassembly NOTE: The connecting rod bolts and nuts cannot be reused. NOTE: Mark the position of the parts, so they can be installed in their original positions. 1. Remove the connecting rod bearings from the connecting rod and cap. 2. Remove the piston rings from the piston. 3. Using the special tool, press the piston pin out of the connecting rod and piston assembly. Assembly Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2005 NOTE: Lubricate all parts with clean engine oil. NOTE: Install the piston in the connecting rod with the cylinder number side of the rod and the indentation notch in the piston on the same side. NOTE: The oil hole in the connecting rod must face the RH side of the cylinder block and the arrow on the piston must face the front of the engine block. 1. NOTE: If the piston pin is removed from the piston, a new piston and piston pin must be used. Do not reuse the piston or the piston pin. Gradually heat the pin bore side of the connecting rod to approximately 232°C-316°C (467°F-626°F) and immediately install the piston pin. 2. Using the special tool, press the piston pin into the piston and connecting rod assembly. 3. Install the piston rings. 4. Make sure the ring gaps (oil spacer-A, oil ring-B, compression ring-C) are correctly spaced around the circumference of the piston. 5. Install the connecting rod bearings in the connecting rod and cap. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Piston pin bore diameter ............................................................................................................................................ 23.958-23.976 mm (0.943-0.944 inch) Piston pin diameter (red) ....................................................................................................................................... 23.994-23.997 mm (0.9446-0.9448 inch) Piston pin diameter (blue) ..................................................................................................................................... 23.997-24.000 mm (0.9448-0.9449 inch) Piston pin length ......................................................................................... ....................................................................... 72.0-72.8 mm (2.835-2.866 inch) Piston pin-to-piston fit ................................................................................................................................................. 0.01-0.016 mm (0.0004-0.0006 inch) Piston pin-to-connecting rod clearance ....................................................................................................................... 0.01-0.016 mm (0.0004-0.0006 inch) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Piston ring end gap - top ............................................................................................................................................... 0.200-0.450 mm (0.008-0.018 inch) Piston ring end gap - bottom ............................................................................................................................................. 0.40-0.60 mm (0.016-0.024 inch) Piston ring groove width - top ....................................................................................................................................... 1.23-1.25 mm (0.0484-0.0492 inch) Piston ring groove width - bottom ................................................................................................................................. 1.52-1.54 mm (0.0598-0.0606 inch) Piston ring groove width - oil ring ................................................................................................................................ 3.01-3.03 mm (0.1185-0.1193 inch) Piston ring width - top ............................................................................................................................................... 1.175-1.190 mm (0.0463-0.0469 inch) Piston ring width - bottom ......................................................................................................................................... 1.475-1.490 mm (0.0581-0.0587 inch) Piston ring-to-groove clearance - top ........................................................................................................................ 0.040-0.075 mm (0.0016-0.0030 inch) Piston ring-to-groove clearance - bottom .................................................................................................................. 0.030-0.065 mm (0.0012-0.0026 inch) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE 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. - 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, which can cause a fire hazard. Failure to follow these instructions may result in personal injury. 1. NOTE: The front passenger door frame scuff plate is retained only by internal metal clips. Remove the front passenger door frame scuff plate. 2. NOTE: - The front passenger door side interior kick panel is retained only by internal metal clips. - It may be necessary to reposition the lower end of the door jam weather stripping to remove the front passenger door side interior kick panel. Remove the front passenger side interior kick panel. 3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Start the engine and allow it to idle until it stalls. 5. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail pressure has been released. 6. Turn the ignition switch to the OFF position. 7. When the fuel system service is complete, reconnect the IFS switch electrical connector. 8. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 9. Start the vehicle and check the fuel system for leaks. 10. Install the front passenger side interior kick panel. 11. Install the front passenger door frame scuff plate. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Camshaft Roller Follower Special Tools Material Removal and Installation 1. Remove the LH and RH valve covers. 2. Remove the fuel rail. 3. Remove the cooling fan. 4. Rotate the crankshaft until the camshaft for the cylinder being serviced is at base circle. 5. NOTE: Mark each camshaft roller follower to make sure it is returned to its original position. Using the special tool, remove the camshaft roller followers. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Page 2019 6. NOTE: The camshaft roller followers must be installed in their original positions. NOTE: Lubricate the camshaft roller followers with clean engine oil. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH Valve Cover: Service and Repair Valve Cover - LH Valve Cover - LH Valve Cover - LH (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 2024 Valve Cover - LH (Part 2) Removal and Installation 1. Remove the intake manifold. 2. Disconnect the camshaft position (CMP) sensor electrical connector. 3. Disconnect the ignition coil electrical connector. Detach the wiring harness retainer. 4. Disconnect the fuel injector electrical connectors. Detach the wiring harness retainers. 5. Remove the positive crankcase ventilation (PCV) valve tube. 6. Disconnect the PCV valve electrical connector. 7. Detach the spark plug wire retainers. 8. Remove the bolts and the valve cover. ^ To install, tighten to 10 Nm (89 inch lbs.). 9. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of the old valve cover gasket. Clean and inspect the sealing surfaces and the gasket. Install a new gasket if necessary. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 2025 10. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 2026 Valve Cover: Service and Repair Valve Cover - RH Valve Cover - RH Material Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 2027 Removal and Installation 1. Disconnect the spring lock coupling from the fuel supply tube. 2. Remove the intake manifold. 3. Remove the heater hose tube bracket rear bolt. ^ To install, tighten to 23 Nm (17 ft. lbs.). 4. Remove the heater hose tube bracket front bolt. ^ To install, tighten to 34 Nm (25 ft. lbs.). 5. Loosen the exhaust manifold-to-exhaust gas recirculation (EGR) system module tube lower fitting and remove the tube. ^ To install, tighten to 34 Nm (25 ft. lbs.). 6. 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. Remove the fuel supply tube-to-valve cover bracket bolt, the fuel supply tube-to-fuel rail bolts and the fuel supply tube. Remove and discard the O-ring seals. ^ Install new O-ring seals and lubricate them with clean engine oil. ^ To install, tighten to 6 Nm (53 inch lbs.). 7. Detach the spark plug wire retainers and position the spark plug wires aside. 8. Remove the crankcase ventilation tube. 9. Remove the bolts and the valve cover. ^ To install, tighten to 10 Nm (89 inch lbs.). 10. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches which make leak paths. Use a plastic scraping tool to remove all traces of the old valve cover gasket. Clean and inspect the sealing surfaces and the gasket. Install a new gasket if necessary. 11. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Service and Repair > Valve Guide Inner Diameter Valve Guide: Service and Repair Valve Guide Inner Diameter Valve Guide Inner Diameter 1. NOTE: Valve guides tend to wear in an hourglass pattern. The ball gauge can be inserted into the combustion chamber side of the valve guide if necessary. Use a ball gauge to determine the inner diameter of the valve guides in 2 directions at the top, middle and bottom of the valve guide. 2. Measure the ball gauge with a micrometer. 3. If the valve guide is not within specifications, ream the valve guide and install a valve with an oversize stem or remove the valve guide and install a new valve guide. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Service and Repair > Valve Guide Inner Diameter > Page 2032 Valve Guide: Service and Repair Valve Guide Reaming Valve Guide Reaming 1. Use a hand-reaming kit to ream the valve guide. 2. Reface the valve seat. 3. Clean the sharp edges left by reaming. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Service and Repair > Valve Seat Inspection Valve Seat: Service and Repair Valve Seat Inspection Valve Seat Inspection Valve and Seat Refacing Measurements CAUTION: After grinding valves or valve seats, check valve clearance. 1. Check the valve head and seat. ^ Check valve angles. ^ Check margin width. ^ Be sure margin width is within specification. 2. Inspect for abnormalities on the valve face and seat. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Service and Repair > Valve Seat Inspection > Page 2037 Valve Seat: Service and Repair Valve Seat Width Valve Seat Width 1. Measure the valve seat width. If necessary, grind the valve seat to specification. ^ Measure the intake valve seat width. ^ Measure the exhaust valve seat width. ^ Recheck the valve spring installed length after the seats have been ground, and shim the valve springs as necessary to achieve the correct installed spring length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Service and Repair > Valve Seat Inspection > Page 2038 Valve Seat: Service and Repair Valve Seat Runout Valve Seat Runout 1. Use a valve seat runout gauge to check valve seat runout. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Valve Spring Installed Length Valve Spring: Service and Repair Valve Spring Installed Length Valve Spring Installed Length 1. Measure the installed length of each valve spring. ^ If out of specification, install new components. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Valve Spring Installed Length > Page 2043 Valve Spring: Service and Repair Valve Springs Valve Springs Special Tools Material Removal and Installation 1. Remove the camshaft roller followers. 2. Position the piston of the cylinder being serviced at top dead center (TDC). 3. 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. Hold the valves in the cylinder head. ^ Remove the spark plug of the cylinder being serviced. ^ Use a suitable tool to apply air pressure to the cylinder. 4. Using the special tool, remove the valve spring retainer keys, valve spring retainers and the valve springs. 5. NOTE: Lubricate the valve springs, retainers and retainer keys with clean engine oil. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Valve Spring Installed Length > Page 2044 Valve Spring: Service and Repair Valve Spring Free Length Valve Spring Free Length 1. Measure the free length of each valve spring. ^ If out of specification, install new components as necessary. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Valve Spring Installed Length > Page 2045 Valve Spring: Service and Repair Valve Spring Squareness Valve Spring Squareness 1. Measure the out-of-square on each valve spring. ^ Turn the valve spring and observe the space between the top of the valve spring and the square. Install a new valve spring if out of square. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Valve Spring Installed Length > Page 2046 Valve Spring: Service and Repair Valve Spring Strength Valve Spring Strength Special Tool(s) 1. Use a spring tester to check the valve spring for correct strength at the specified valve spring length. ^ If out of specification, install new components as necessary. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Testing and Inspection Valve: Testing and Inspection Valve Inspection 1. Inspect the following valve areas: 1 The end of the stem for grooves or scoring 2 The valve face and the edge for pits, grooves or scores 3 The valve head for signs of burning, erosion, warpage and cracking 4 The valve margin for wear Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Valve Stem Diameter Valve: Service and Repair Valve Stem Diameter Valve Stem Diameter 1. Measure the diameter of each intake and exhaust valve stem at the points shown. Verify the diameter is within specification. ^ If out of specification, install new components as necessary. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Valve Stem Diameter > Page 2052 Valve: Service and Repair Valve Stem to Valve Guide Clearance Valve Stem to Valve Guide Clearance Special Tools NOTE: Valve stem diameter must be within specifications before checking valve stem to valve guide clearance. 1. NOTE: If necessary, use a magnetic base. Install a valve clearance gauge on the valve stem and install a dial indicator. Lower the valve until the valve clearance gauge contacts the upper surface of the valve guide. 2. Move the valve clearance gauge toward the indicator and zero the indicator. Move the valve clearance gauge away from the indicator and note the reading. The reading will be DOUBLE the valve stem-to-valve guide clearance. Valves with oversize stems will need to be installed if out of specification. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 09-7-7 > Apr > 09 > Engine - Squeal/Chirp On Cold Start Up Drive Belt: Customer Interest Engine - Squeal/Chirp On Cold Start Up TSB 09-7-7 04/20/09 4.0L ENGINE BELT SQUEAL OR CHIRP NOISE ON COLD STARTUP FORD: 2009 Mustang 2007-2008 Explorer Sport Trac, Explorer MERCURY: 2007-2008 Mountaineer ISSUE Some 2007-2008 Explorer, Explorer Sport Trac, Mountaineer and 2009 Mustang vehicles equipped with a 4.0L engine may exhibit a belt squeal or belt chirp from the front end accessory drive (FEAD) belt near the power steering pulley area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE UNDER NO CIRCUMSTANCES SHOULD THE ACCESSORY DRIVE BELT, TENSIONER OR PULLEYS HAVE ANY FLUIDS OR BELT DRESSING APPLIED TO THEM AS DAMAGE TO THE BELT MATERIAL AND TENSIONER DAMPING MECHANISM MAY OCCUR. 1. Visually inspect all related FEAD components for damage and or abnormal wear. Reference the online Work Shop Manual (WSM), Section 303-05.If no concerns found, proceed to Step 2. 2. Inspect for FEAD belt clearance on the idler pulley. A properly aligned belt will have an approximate 3/32" (2 mm) space behind the belt on the idler pulley. (Figure 1) a. If there is not an approximate 3/32" (2 mm) gap, proceed with Step 3. b. If there is an approximate 3/32" (2 mm) gap, proceed with Step 5. 3. Verify the generator bracket and idler pulley are properly seated and torqued to specification. Reference the online (WSM), Section 303-05. a. If they are not properly seated or torqued to specification, after correcting them, remeasure the gap per Step 2. (1) If the gap is still not 3/32" (2 mm), proceed to Step 4. (2) If there is an approximate 3/32" (2 mm) gap, proceed to Step 5. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 09-7-7 > Apr > 09 > Engine - Squeal/Chirp On Cold Start Up > Page 2062 b. If no concerns are found with fit or torque, proceed to Step 4. 4. Replace the generator bracket with updated bracket. Reference online (WSM), Section 303-01. Proceed to Step 5. 5. Replace the accessory drive belt with the updated belt part number. Reference online (WSM), Section 303-05. Parts Block 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 090707A 2009 Mustang, 2007-2008 0.3 Hr. Explorer, Explorer Sport Trac, Mountaineer 4.0L: Inspect And Replace FEAD Belt Includes Time For Measurements (Do Not Use With 10346A, 6209A, 8678A, 8620F) 090707B 2009 Mustang, 2007-2008 0.8 Hr. Explorer, Explorer Sport Trac, Mountaineer 4.0L: Inspect And Replace Alternator Bracket And FEAD Belt Includes Time For Measurements (Do Not Use With 10346A, 6209A, 8678A, 8620F) DEALER CODING CONDITION BASIC PART NO. CODE 10A313 07 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 09-7-7 > Apr > 09 > Engine - Squeal/Chirp On Cold Start Up Drive Belt: All Technical Service Bulletins Engine - Squeal/Chirp On Cold Start Up TSB 09-7-7 04/20/09 4.0L ENGINE BELT SQUEAL OR CHIRP NOISE ON COLD STARTUP FORD: 2009 Mustang 2007-2008 Explorer Sport Trac, Explorer MERCURY: 2007-2008 Mountaineer ISSUE Some 2007-2008 Explorer, Explorer Sport Trac, Mountaineer and 2009 Mustang vehicles equipped with a 4.0L engine may exhibit a belt squeal or belt chirp from the front end accessory drive (FEAD) belt near the power steering pulley area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE UNDER NO CIRCUMSTANCES SHOULD THE ACCESSORY DRIVE BELT, TENSIONER OR PULLEYS HAVE ANY FLUIDS OR BELT DRESSING APPLIED TO THEM AS DAMAGE TO THE BELT MATERIAL AND TENSIONER DAMPING MECHANISM MAY OCCUR. 1. Visually inspect all related FEAD components for damage and or abnormal wear. Reference the online Work Shop Manual (WSM), Section 303-05.If no concerns found, proceed to Step 2. 2. Inspect for FEAD belt clearance on the idler pulley. A properly aligned belt will have an approximate 3/32" (2 mm) space behind the belt on the idler pulley. (Figure 1) a. If there is not an approximate 3/32" (2 mm) gap, proceed with Step 3. b. If there is an approximate 3/32" (2 mm) gap, proceed with Step 5. 3. Verify the generator bracket and idler pulley are properly seated and torqued to specification. Reference the online (WSM), Section 303-05. a. If they are not properly seated or torqued to specification, after correcting them, remeasure the gap per Step 2. (1) If the gap is still not 3/32" (2 mm), proceed to Step 4. (2) If there is an approximate 3/32" (2 mm) gap, proceed to Step 5. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 09-7-7 > Apr > 09 > Engine - Squeal/Chirp On Cold Start Up > Page 2068 b. If no concerns are found with fit or torque, proceed to Step 4. 4. Replace the generator bracket with updated bracket. Reference online (WSM), Section 303-01. Proceed to Step 5. 5. Replace the accessory drive belt with the updated belt part number. Reference online (WSM), Section 303-05. Parts Block 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 090707A 2009 Mustang, 2007-2008 0.3 Hr. Explorer, Explorer Sport Trac, Mountaineer 4.0L: Inspect And Replace FEAD Belt Includes Time For Measurements (Do Not Use With 10346A, 6209A, 8678A, 8620F) 090707B 2009 Mustang, 2007-2008 0.8 Hr. Explorer, Explorer Sport Trac, Mountaineer 4.0L: Inspect And Replace Alternator Bracket And FEAD Belt Includes Time For Measurements (Do Not Use With 10346A, 6209A, 8678A, 8620F) DEALER CODING CONDITION BASIC PART NO. CODE 10A313 07 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 2069 Drive Belt: Diagrams Front End Accessory Drive (FEAD) - Exploded View, 4.0L SOHC Front End Accessory Drive (FEAD) - Exploded View, 4.0L SOHC Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Accessory Drive Inspection and Verification CAUTION: Under no circumstances should the accessory drive belt, tensioner or pulleys be lubricated as potential damage to the belt material and tensioner damping mechanism will occur. Do not apply any fluids or belt dressing to the accessory drive belt or pulleys. 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical damage. Visual Inspection Chart Visual Inspection Chart 3. Eliminate all other non-belt related noises that could cause belt misdiagnosis, such as A/C compressor engagement chirp, power steering cavitations at low temperatures, variable camshaft timing (VCT) tick or generator whine. 4. If a concern is found, correct the condition before proceeding to the next step. V-Ribbed Serpentine Drive Belt With Cracks Across Ribs V-Ribbed Serpentine Drive Belt With Cracks Across Ribs 5. NOTE: Up to 15 cracks in a rib over a distance of 100 mm (4.0 inch) can be considered acceptable. If damage exceeds the acceptable limit or any chunks are found to be missing from the ribs, a new belt must be installed. Check the belt for cracks. Up to 15 cracks in a rib over a distance of 100 mm (4.0 inch) can be considered acceptable. If cracks exceed this standard, install a new belt. 6. The condition of the V-ribbed drive belt should be compared against the illustration and appropriate action taken. 1 Small scattered deposits of rubber material. This is not a concern, therefore, installation of a new belt is not required. 2 Longer deposit areas building up to 50% of the rib height. This is not considered a concern but it can result in excessive noise. If noise is apparent, install a new belt. 3 Heavy deposits building up along the grooves resulting in a possible noise and belt stability concern. If heavy deposits are apparent, install a new belt. V-Ribbed Serpentine Belt With Piling NOTE: Piling is an excessive buildup in the V-grooves of the belt. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 2072 V-Ribbed Serpentine Belt With Piling 7. There should be no chunks missing from the belt ribs. If the belt shows any evidence of this, install a new accessory drive belt. V-Ribbed Serpentine Belt With Chunks of Rib Missing V-Ribbed Serpentine Belt With Chunks Of Rib Missing 8. If the concern is not visually evident, verify the symptom and GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 2073 Drive Belt: Symptom Related Diagnostic Procedures Symptom Chart (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 2074 Symptom Chart (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 2075 Drive Belt: Component Tests and General Diagnostics Drive Belt - Noise/Flutter Drive Belt - Noise/Flutter Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a damaged or incorrectly aligned grooved pulley. To correct, determine the area where the noise comes from. Check each of the pulleys in that area with a straightedge to the crankshaft pulley. Look for accessory pulleys out of position in the fore/aft direction or at an angle to the straightedge. CAUTION: Do not apply any fluids or belt dressing to the accessory drive belt or pulleys. Drive belt squeal may be an intermittent or constant noise that occurs when the drive belt slips on an accessory pulley under certain conditions. A short intermittent squeal may occur during engine start-up and shut down or during very rapid engine acceleration and decelerations, such as: ^ wide open throttle 1-2 and 2-3 shifts or 2-3 and 3-4 back out shifts on automatic transmissions. ^ wide open throttle 1-2 and 2-3 shifts and any combination of rapid downshifting on manual transmissions. These special short-term transient events are expected, and are due to the higher system inertias required to meet the electrical and cooling demands on today's vehicle systems. Constant or reoccurring drive belt squeal can occur: ^ if the A/C discharge pressure goes above specifications: ^ the A/C system is overcharged. ^ the A/C condenser core airflow is blocked. ^ if the A/C off equalized pressure (the common discharged and suction pressure that occurs after several minutes) exceeds specifications. ^ if any of the accessories are damaged or have a worn or damaged bearing. All accessories should be rotatable by hand in the unloaded condition. If not, inspect the accessory. ^ if there is evidence of fluid contamination on the accessory drive belt. When the drive belt has been exposed to fluid contamination during vehicle operation, such as leaks from the power steering system, A/C system or cooling system, clean all pulleys with soap and water, rinse with clean water and install a new accessory drive belt. If the drive belt has been exposed to fluids in a localized area during routine vehicle service, such as replacement of hoses or fluids, the drive belt and pulleys should be washed with soap and water immediately (prior to starting the engine), and rinsed with clean water. ^ if the accessory drive belt is too long. A drive belt that is too long will allow the accessory drive belt tensioner arm to go all the way to the arm travel stop under certain load conditions, which will release tension to the drive belt. If the accessory drive belt tensioner indicator is outside the normal installation wear range window, install a new accessory drive belt. ^ NOTE: The accessory drive belt tensioner arm should rotate freely without binding. Install a new accessory drive belt tensioner if the drive belt tensioner is worn or damaged. Drive Belt - Incorrect Installation Drive Belt - Incorrect Installation CAUTION: Incorrect accessory drive belt installation will cause excessive drive belt wear and can cause the drive belt to come off the pulleys. Non-standard accessory drive belts can track differently or incorrectly. If an accessory drive belt tracks incorrectly, install a new accessory drive belt to avoid performance failure or loss of the drive belt. Incorrect Installation Incorrect Installation Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 2076 Correct Installation Correct Installation With the engine running, check accessory drive belt tracking on all pulleys. If the edge of the accessory drive belt rides beyond the edge of the pulleys, noise and premature wear will occur. Make sure the accessory drive belt rides correctly on the pulley. If an accessory drive belt tracking condition exists, proceed with the following: ^ Visually check the accessory drive belt tensioner for damage, especially the mounting pad surface. If the accessory drive belt tensioner is not installed correctly, the mounting surface pad will be out of position. This will result in chirp and squeal noises. ^ With the engine running, visually observe the grooves in the pulleys (not the pulley flanges or the pulley forward faces) for excessive wobble. Install new components as necessary. ^ Check all accessories, mounting brackets and the accessory drive belt tensioner for any interference that would prevent the component from mounting correctly. Correct any interference condition and recheck the accessory drive belt tracking. ^ Tighten all accessories, mounting brackets and accessory drive belt tensioner retaining hardware to specification. Recheck the accessory drive belt tracking. Belt Tensioner - Mechanical Belt Tensioner - Mechanical The only mechanical check that needs to be made is a check for tensioner stick, grab or bind. 1. With the engine off, check routing of the accessory drive belt. Refer to the illustrations under Description and Operation. 2. NOTE: The accessory drive belt tensioner spring is very strong and requires substantial force to release. Using a suitable, commercially available serpentine belt tensioner release tool, release the tension on the belt and detach the accessory drive belt in the area of the tensioner. 3. Using a suitable, commercially available serpentine belt tensioner release tool, move the tensioner from its relaxed position, through its full stroke and back to the relaxed position to make sure there is no stick, grab or bind, and to make sure that there is tension on the tensioner spring. 4. Rotate the tensioner pulley by hand and check for a binding, contaminated or seized condition. Install a new accessory drive belt tensioner if necessary. 5. Inspect the area surrounding the accessory drive belt tensioner for oil leaks or contamination and repair any leaks. Install a new accessory drive belt tensioner as necessary. 6. If the accessory drive belt tensioner meets the above criteria, proceed to testing the tensioner dynamically. If the accessory drive belt tensioner does not meet the above criteria, install a new tensioner. Belt Tensioner - Dynamics Belt Tensioner - Dynamics The accessory drive belt tensioner can be checked dynamically as follows: 1. With the engine running, observe the accessory drive belt tensioner movement. The accessory drive tensioner should move (respond) when the air conditioning clutch cycles (if equipped), or when the engine is accelerated rapidly. If the accessory drive belt tensioner movement is excessive without air conditioning clutch cycling or engine acceleration, check belt rideout. Excessive belt rideout (uneven depth of grooves in the belt) can cause excessive accessory drive belt tensioner movement. Check rideout condition by installing a new belt. If excessive accessory drive belt tensioner movement still exists, install a new accessory drive belt tensioner. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 2077 Drive Belt: Service and Repair Accessory Drive Belt - 4.0L SOHC Removal and Installation 1. Rotate the accessory drive belt tensioner counterclockwise and remove the drive belt. 2. To install, reverse the removal procedure. ^ For correct belt routing, refer to Accessory Drive, Component Locations - 4.0L SOHC. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair Drive Belt Tensioner: Service and Repair Accessory Drive Belt Tensioner - 4.0L SOHC Removal and Installation 1. Rotate the accessory drive belt tensioner counterclockwise and remove the drive belt. 2. Remove the bolt and the accessory drive belt tensioner. ^ To install, tighten the bolt to 47 Nm (35 ft. lbs.). 3. To install, reverse the removal procedure. ^ For correct belt routing, refer to Accessory Drive, Component Locations - 4.0L SOHC in the Description and Operation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > Customer Interest: > 09-7-7 > Apr > 09 > Engine - Squeal/Chirp On Cold Start Up Engine Accessory Bracket: Customer Interest Engine - Squeal/Chirp On Cold Start Up TSB 09-7-7 04/20/09 4.0L ENGINE BELT SQUEAL OR CHIRP NOISE ON COLD STARTUP FORD: 2009 Mustang 2007-2008 Explorer Sport Trac, Explorer MERCURY: 2007-2008 Mountaineer ISSUE Some 2007-2008 Explorer, Explorer Sport Trac, Mountaineer and 2009 Mustang vehicles equipped with a 4.0L engine may exhibit a belt squeal or belt chirp from the front end accessory drive (FEAD) belt near the power steering pulley area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE UNDER NO CIRCUMSTANCES SHOULD THE ACCESSORY DRIVE BELT, TENSIONER OR PULLEYS HAVE ANY FLUIDS OR BELT DRESSING APPLIED TO THEM AS DAMAGE TO THE BELT MATERIAL AND TENSIONER DAMPING MECHANISM MAY OCCUR. 1. Visually inspect all related FEAD components for damage and or abnormal wear. Reference the online Work Shop Manual (WSM), Section 303-05.If no concerns found, proceed to Step 2. 2. Inspect for FEAD belt clearance on the idler pulley. A properly aligned belt will have an approximate 3/32" (2 mm) space behind the belt on the idler pulley. (Figure 1) a. If there is not an approximate 3/32" (2 mm) gap, proceed with Step 3. b. If there is an approximate 3/32" (2 mm) gap, proceed with Step 5. 3. Verify the generator bracket and idler pulley are properly seated and torqued to specification. Reference the online (WSM), Section 303-05. a. If they are not properly seated or torqued to specification, after correcting them, remeasure the gap per Step 2. (1) If the gap is still not 3/32" (2 mm), proceed to Step 4. (2) If there is an approximate 3/32" (2 mm) gap, proceed to Step 5. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > Customer Interest: > 09-7-7 > Apr > 09 > Engine - Squeal/Chirp On Cold Start Up > Page 2089 b. If no concerns are found with fit or torque, proceed to Step 4. 4. Replace the generator bracket with updated bracket. Reference online (WSM), Section 303-01. Proceed to Step 5. 5. Replace the accessory drive belt with the updated belt part number. Reference online (WSM), Section 303-05. Parts Block 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 090707A 2009 Mustang, 2007-2008 0.3 Hr. Explorer, Explorer Sport Trac, Mountaineer 4.0L: Inspect And Replace FEAD Belt Includes Time For Measurements (Do Not Use With 10346A, 6209A, 8678A, 8620F) 090707B 2009 Mustang, 2007-2008 0.8 Hr. Explorer, Explorer Sport Trac, Mountaineer 4.0L: Inspect And Replace Alternator Bracket And FEAD Belt Includes Time For Measurements (Do Not Use With 10346A, 6209A, 8678A, 8620F) DEALER CODING CONDITION BASIC PART NO. CODE 10A313 07 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-7-7 > Apr > 09 > Engine - Squeal/Chirp On Cold Start Up Engine Accessory Bracket: All Technical Service Bulletins Engine - Squeal/Chirp On Cold Start Up TSB 09-7-7 04/20/09 4.0L ENGINE BELT SQUEAL OR CHIRP NOISE ON COLD STARTUP FORD: 2009 Mustang 2007-2008 Explorer Sport Trac, Explorer MERCURY: 2007-2008 Mountaineer ISSUE Some 2007-2008 Explorer, Explorer Sport Trac, Mountaineer and 2009 Mustang vehicles equipped with a 4.0L engine may exhibit a belt squeal or belt chirp from the front end accessory drive (FEAD) belt near the power steering pulley area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE UNDER NO CIRCUMSTANCES SHOULD THE ACCESSORY DRIVE BELT, TENSIONER OR PULLEYS HAVE ANY FLUIDS OR BELT DRESSING APPLIED TO THEM AS DAMAGE TO THE BELT MATERIAL AND TENSIONER DAMPING MECHANISM MAY OCCUR. 1. Visually inspect all related FEAD components for damage and or abnormal wear. Reference the online Work Shop Manual (WSM), Section 303-05.If no concerns found, proceed to Step 2. 2. Inspect for FEAD belt clearance on the idler pulley. A properly aligned belt will have an approximate 3/32" (2 mm) space behind the belt on the idler pulley. (Figure 1) a. If there is not an approximate 3/32" (2 mm) gap, proceed with Step 3. b. If there is an approximate 3/32" (2 mm) gap, proceed with Step 5. 3. Verify the generator bracket and idler pulley are properly seated and torqued to specification. Reference the online (WSM), Section 303-05. a. If they are not properly seated or torqued to specification, after correcting them, remeasure the gap per Step 2. (1) If the gap is still not 3/32" (2 mm), proceed to Step 4. (2) If there is an approximate 3/32" (2 mm) gap, proceed to Step 5. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-7-7 > Apr > 09 > Engine - Squeal/Chirp On Cold Start Up > Page 2095 b. If no concerns are found with fit or torque, proceed to Step 4. 4. Replace the generator bracket with updated bracket. Reference online (WSM), Section 303-01. Proceed to Step 5. 5. Replace the accessory drive belt with the updated belt part number. Reference online (WSM), Section 303-05. Parts Block 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 090707A 2009 Mustang, 2007-2008 0.3 Hr. Explorer, Explorer Sport Trac, Mountaineer 4.0L: Inspect And Replace FEAD Belt Includes Time For Measurements (Do Not Use With 10346A, 6209A, 8678A, 8620F) 090707B 2009 Mustang, 2007-2008 0.8 Hr. Explorer, Explorer Sport Trac, Mountaineer 4.0L: Inspect And Replace Alternator Bracket And FEAD Belt Includes Time For Measurements (Do Not Use With 10346A, 6209A, 8678A, 8620F) DEALER CODING CONDITION BASIC PART NO. CODE 10A313 07 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Accessory Bracket: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets Fuel Distance/Mileage Module: All Technical Service Bulletins Instruments - Trip Odometers/Fuel Economy Resets TSB 09-21-7 11/02/09 TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS UNINTENTIONALLY FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally. This condition may occur if there is an intermittent electrical connection on the power feed to the cluster or if the reset button on the 3-button message center assembly is momentarily touched. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. With the key in the On position, display the trip odometer mileage. 2. Start the vehicle. 3. Cycle the key back Off and restart the vehicle. 4. Verify whether the trip mileage reset or not. 5. If not, proceed to Step 10. 6. If it reset, turn the key Off and remove the key from the ignition. 7. Activate the emergency flashers. 8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal fuse and wiring diagnostics to correct the power feed circuit. 9. Verify repair and proceed to Step 10. 10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release 63.07 and higher. This new calibration is not included in the VCM 2009.9 DVD. Calibration files may also be obtained at the website. NOTE REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT RESOLVE THIS ISSUE. 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 092107A 2006-2010 Explorer, 0.3 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Accessory Bracket: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 2101 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Accessory Bracket: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 2107 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Cylinder Block Cradle Engine Mount: Service and Repair Cylinder Block Cradle Cylinder Block Cradle Special Tools Material Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair 2. Disconnect the battery ground cable. 3. Remove the air cleaner outlet tube. 4. Remove the starter. 5. Remove the oil pump screen and pickup tube. 6. Remove the weatherstrip. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Cylinder Block Cradle > Page 2112 7. Remove the bolt and position the power steering fluid reservoir aside. 8. CAUTION: Allow the engine to cool before removing the coolant expansion tank. The radiator draws coolant from the coolant expansion tank as the engine cools. If the coolant expansion tank is removed before the engine cools, the radiator will draw air into the system, resulting in possible engine damage. Disconnect the coolant overflow hose. Remove the bolts and the coolant expansion tank. 9. Remove the bolts, unclip the clips and remove the upper fan shroud. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Cylinder Block Cradle > Page 2113 10. Remove the bolt. 11. Install the special tool using the previously removed bolt. ^ Tighten to 23 Nm (17 ft. lbs.). 12. NOTE: This is not a typical setup. Only the right side of the engine will be raised. Install the special tools. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Cylinder Block Cradle > Page 2114 All wheel drive (AWD) vehicles 13. Remove the bolts and the stabilizer bar brackets. 14. Remove the bolts and the crossmember. All vehicles 15. Remove the RH engine support insulator nut. 16. Remove the LH engine support insulator through bolt. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Cylinder Block Cradle > Page 2115 17. Remove the 2 transmission-to-cylinder block cradle bolts. 18. NOTE: Cylinder block cradle is shown removed for clarity. Note the location of the 2 Torx(R) head bolts at the rear of the cylinder block cradle. Remove the cylinder block cradle rear bolts. 19. Remove the 20 bolts and 2 nuts along the outside of the cylinder block cradle. 20. NOTE: Note the location of the 2 silver-colored bolts that have washer seals. They must be installed in the same position with new washer seals. Remove the 8 cylinder block cradle inner bolts and the 2 washer seals. ^ Discard the washer seals. 21. Raise the engine. AWD vehicles 22. WARNING: Secure the axle to the jack with a safety strap. Failure to follow these instructions may result in personal injury. Support the front axle with a suitable jack stand. 23. Disconnect the vent hose from the differential housing vent tube. 24. Remove and discard the axle housing bolts and nuts. Lower the axle. All vehicles 25. Remove the cylinder block cradle. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Cylinder Block Cradle > Page 2116 Installation All vehicles 1. CAUTION: Failure to back off the set screws can result in damage to the cylinder block cradle. Back the set screws off until they are below the cylinder block cradle boss. 2. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of the old cylinder block cradle gasket and sealant. NOTE: Gasket material as well as silicone sealant may be present in the cavities in the main bearing cap. This material must be removed completely prior to assembly. Clean the gasket mating surfaces, making sure all the sealant is removed from the cavities on the rear main bearing cap. To clean the sealing area, use a plastic scraping tool, silicone gasket remover and metal surface prep. Follow the directions on the packaging. 3. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage. Apply silicone in the 6 places shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Cylinder Block Cradle > Page 2117 4. Position a new gasket and the cylinder block cradle. Install the outer 20 bolts and 2 nuts finger-tight. 5. Install the 2 cylinder block cradle rear Torx(R) bolts finger-tight. 6. Install the 2 transmission-to-cylinder block cradle bolts. ^ Tighten to 47 Nm (35 ft. lbs.). 7. Tighten the outer 20 bolts and 2 nuts. ^ Tighten the nuts to 10 Nm (89 inch lbs.). ^ Tighten the bolts to 14 Nm (10 ft. lbs.). 8. Tighten the 2 cylinder block cradle rear Torx(R) bolts. ^ Tighten to 8 Nm (71 inch lbs.). 9. Tighten the 8 inserts. ^ Tighten to 3 Nm (27 inch lbs.). 10. Install the 2 silver-colored bolts and new washer seals finger-tight. 11. Install the 6 remaining inner bolts finger-tight. 12. Tighten the 8 inner bolts in the sequence shown in 2 stages. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Cylinder Block Cradle > Page 2118 ^ Stage 1: Tighten to 15 Nm (11 ft. lbs.). ^ Stage 2: Tighten to 34 Nm (25 ft. lbs.). AWD vehicles 13. Raise the axle into position and install new bolts and nuts. ^ Tighten to 66 Nm (49 ft. lbs.). 14. Connect the vent hose to the differential housing vent tube. All vehicles 15. Lower the engine and remove the special tools. 16. Install the LH engine support insulator through bolt and nut. ^ Tighten to 103 Nm (76 ft. lbs.). 17. Install the RH engine support insulator nut. ^ Tighten to 90 Nm (66 ft. lbs.). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Cylinder Block Cradle > Page 2119 AWD vehicles 18. Position the crossmember and install the bolts. ^ Tighten to 103 Nm (76 ft. lbs.). 19. Position the stabilizer bar brackets and install the bolts. ^ Tighten to 55 Nm (41 ft. lbs.). All vehicles 20. Install the oil pump screen and pickup tube. 21. Install the starter. 22. Remove the special tool. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Cylinder Block Cradle > Page 2120 23. Install the heater hose tube bracket front bolt. ^ Tighten to 34 Nm (25 ft. lbs.). 24. Position the upper fan shroud and install the bolts. ^ Tighten to 7 Nm (62 inch lbs.). 25. Position the coolant expansion tank, install the bolts and connect the coolant overflow hose. ^ Tighten to 7 Nm (62 inch lbs.). 26. Position the power steering fluid reservoir and install the bolt. ^ Tighten to 7 Nm (62 inch lbs.). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Cylinder Block Cradle > Page 2121 27. Install the weatherstrip. 28. Install the air cleaner outlet pipe. 29. Connect the battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Cylinder Block Cradle > Page 2122 Engine Mount: Service and Repair Engine Support Insulators Engine Support Insulators Special Tools Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Cylinder Block Cradle > Page 2123 Four Wheel Drive (4WD) Vehicles Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Cylinder Block Cradle > Page 2124 All Vehicles (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Cylinder Block Cradle > Page 2125 All Vehicles (Part 2) Removal and Installation CAUTION: Any time bolts, washers, spacers or nuts are loosened in the differential support for any reason, install new components to prevent damage. All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair 2. Disconnect the battery ground cable. For additional information, refer to Battery. 3. Remove the weatherstrip. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Cylinder Block Cradle > Page 2126 4. Remove the bolt and position the power steering fluid reservoir aside. ^ To install, tighten to 7 Nm (62 inch lbs.). 5. CAUTION: Allow the engine to cool before removing the coolant expansion tank. The radiator draws coolant from the coolant expansion tank as the engine cools. If the coolant expansion tank is removed before the engine cools, the radiator will draw air into the system, resulting in possible engine damage. Disconnect the coolant overflow hose. Remove the bolts and the coolant expansion tank. ^ To install, tighten to 7 Nm (62 inch lbs.). 6. Remove the bolts, unclip the clips and remove the upper fan shroud. ^ To install, tighten to 7 Nm (62 inch lbs.). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Cylinder Block Cradle > Page 2127 7. Remove the bolt and install the lifting eye. 8. Install the special tools. 9. Remove the LH engine support insulator through bolt. ^ To install, tighten to 103 Nm (76 ft. lbs.). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Cylinder Block Cradle > Page 2128 10. Remove the pushpins and the RH inner fender splash shield. 11. Remove the RH engine support insulator nuts. ^ To install, tighten to 90 Nm (66 ft. lbs.). 12. Raise the engine approximately 60 mm (2.36 inch). 13. Remove the RH engine support insulator. AWD vehicles 14. Remove the bolts and the stabilizer bar brackets. Allow the stabilizer bar to hang freely. 15. WARNING: Secure the axle to the jack with a safety strap. Failure to follow these instructions may result in personal injury. Support the axle with a suitable jack stand. 16. Disconnect the vent hose from the differential housing vent tube. 17. Remove and discard the axle housing bolts. Lower the axle housing approximately 25 mm (1 inch). ^ To install, tighten to 66 Nm (49 ft. lbs.). All vehicles 18. Remove the nut and the LH engine support insulator. ^ To install, tighten to 90 Nm (66 ft. lbs.). 19. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Service and Repair Idler Pulley: Service and Repair Accessory Drive Belt Idler Pulley - 4.0L SOHC Removal and Installation 1. Rotate the accessory drive belt tensioner counterclockwise and remove the drive belt. 2. Remove the bolt and the accessory drive belt idler pulley. ^ To install, tighten to 47 Nm (35 ft. lbs.). 3. To install, reverse the removal procedure. ^ For correct belt routing, refer to Accessory Drive, Component Locations - 4.0L SOHC in the Description and Operation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil pressure minimum at 2,000 rpm (engine at normal operating temperature) ........................................................................................... 103 kPa (15 psi) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 2136 Engine Oil Pressure: Testing and Inspection Oil Pressure Test 1. Disconnect and remove the oil pressure sensor from the engine. 2. Connect the Oil Pressure Gauge to the oil pressure sender oil galley port. 3. Run the engine until normal operating temperature is reached. 4. Run the engine at the specified rpm and record the gauge reading. 5. The oil pressure should be within specifications. 6. If the pressure is not within specification, check the following possible sources: ^ Insufficient oil ^ Oil leakage ^ Worn or damaged oil pump ^ Oil pump screen cover and tube ^ Excessive main bearing clearance ^ Excessive connecting rod bearing clearance Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2141 Engine Oil: Fluid Type Specifications Engine Oil U.S. ......................................................................................................................................... Motorcraft SAE 5W-30 Premium Synthetic Blend Motor Oil Canada .................................................................................................................................................... Motorcraft SAE 5W-30 Super Premium Motor Oil Note: Use of synthetic or synthetic blend motor oil is not mandatory. Engine oil need only have the API Certification mark and meet the requirements of Ford Specification WSS-M2C929-A. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair Oil Cooler: Service and Repair Oil Cooler Material Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair 2. Drain the cooling system. For additional information, refer to Cooling System. 3. Remove and discard the oil filter. ^ To install, tighten to 13 Nm (10 ft. lbs.). 4. Disconnect the oil cooler inlet hose from the oil cooler. 5. Disconnect the heater hose from the oil cooler. 6. Loosen the threaded insert and remove the oil cooler. ^ To install, tighten to 57 Nm (42 ft. lbs.). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Page 2145 7. To install, reverse the removal procedure. ^ Install a new oil filter. ^ Check the engine oil and fill as necessary. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair Oil Filter Adapter: Service and Repair Oil Filter Adapter Material Removal and Installation All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair 2. Remove and discard the oil filter. ^ To install, tighten to 13 Nm (10 ft. lbs.). Vehicles equipped with an oil cooler Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Page 2149 3. NOTE: The oil cooler threaded insert is part of the oil cooler and is not removed. Loosen the oil cooler threaded insert and position the oil cooler aside. ^ To install, tighten to 57 Nm (42 ft. lbs.). All vehicles 4. Remove the bolt and the oil filter adapter. ^ To install, tighten to 57 Nm (42 ft. lbs.). 5. To install, reverse the removal procedure. ^ Install a new oil filter. ^ Check the engine oil and fill as necessary. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil pan bolts ......................................................................................................................................... ...................................................... 11 Nm (8 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2153 Oil Pan: Service and Repair Oil Pan Material Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair 2. Remove the drain plug and drain the engine oil. ^ To install, tighten to 26 Nm (19 ft. lbs.). 3. Remove the bolts, the oil pan and the gasket. Discard the gasket. ^ To install, tighten to 11 Nm (8 ft. lbs.). 4. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of the old oil pan gasket. Clean and inspect the sealing surfaces. 5. To install, reverse the removal procedure. 6. Fill the engine with clean engine oil. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations View 151-1 (Engine Compartment - 4.0L, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 2157 C103 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Service and Repair Oil Pick Up/Strainer: Service and Repair Oil Pump Screen and Pickup Tube 1. Remove the oil pan. 2. Remove the bolt and the oil pump screen and pickup tube. ^ To install, tighten to 10 Nm (89 lb-in). 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 minimum at 2,000 rpm (engine at normal operating temperature) ........................................................................................... 103 kPa (15 psi) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 2165 Engine Oil Pressure: Testing and Inspection Oil Pressure Test 1. Disconnect and remove the oil pressure sensor from the engine. 2. Connect the Oil Pressure Gauge to the oil pressure sender oil galley port. 3. Run the engine until normal operating temperature is reached. 4. Run the engine at the specified rpm and record the gauge reading. 5. The oil pressure should be within specifications. 6. If the pressure is not within specification, check the following possible sources: ^ Insufficient oil ^ Oil leakage ^ Worn or damaged oil pump ^ Oil pump screen cover and tube ^ Excessive main bearing clearance ^ Excessive connecting rod bearing clearance Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Sensor/Switch, Engine > Component Information > Description and Operation Oil Temperature Sensor/Switch: Description and Operation ENGINE OIL TEMPERATURE (EOT) SENSOR Typical EOT Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance changes 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 EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system. The PCM can use the EOT sensor input to determine the following: - On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM begins reducing power by disabling engine cylinders. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications Intake Manifold: Specifications Intake manifold bolts ............................................................................................................................ ...................................................... 11 Nm (8 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2172 Intake Manifold: Service and Repair Intake Manifold Intake Manifold (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2173 Intake Manifold (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2174 Intake Manifold (Part 3) Removal and Installation 1. Remove the air cleaner outlet pipe. 2. Detach the knock sensor (KS) electrical connector from the intake manifold. 3. Disconnect the positive crankcase ventilation (PCV) tube from the intake manifold. 4. Disconnect the brake booster vacuum hose from the intake manifold. 5. Disconnect the main vacuum harness fitting from the intake manifold. 6. Disconnect the evaporative emissions (EVAP) tube from the intake manifold. 7. Disconnect the exhaust gas recirculation (EGR) system module electrical connector. 8. Detach the wiring harness retainer. 9. Disconnect the EGR system module vacuum fitting. 10. Loosen the fitting and disconnect the exhaust manifold-to-EGR system module tube from the EGR system module. ^ To install, tighten to 34 Nm (25 ft. lbs.). 11. Disconnect the throttle position (TP) sensor electrical connector. 12. Disconnect the electronic throttle body (TB) electrical connector. 13. Remove the nut and detach the wiring harness bracket from the electronic TB. ^ To install, tighten to 9 Nm (80 inch lbs.). 14. Remove the bolts, the intake manifold and the gaskets. ^ To install, tighten to 11 Nm (8 ft. lbs.). 15. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools can cause scratches and gouges which can make leak paths. Use a plastic scraping tool to remove all traces of the old intake manifold gaskets Clean the sealing surfaces and inspect the gaskets. Install new gaskets if necessary. 16. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Tools Material Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 2179 Removal 1. Remove the flexplate. 2. Remove the spacer plate. 3. Remove the flexplate-to-crankshaft spacer. 4. NOTE: The crankshaft rear seal may have a metal speedy sleeve. This sleeve must be removed before attempting to remove the seal. If necessary, remove the speedy sleeve using 2 screwdrivers or small pry bars. 5. 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. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 2180 Installation 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 oil seal with clean engine oil. 2. Install the special tools. 3. Position the crankshaft rear seal. 4. Using the special tool, install the crankshaft rear seal. 5. Install the flexplate-to-crankshaft spacer. 6. Install the spacer plate. 7. Install the flexplate. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Crankshaft Front Seal Special Tools Material Removal 1. Remove the crankshaft pulley. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 2184 2. Using the special tool, remove and discard the crankshaft front seal. Installation 1. NOTE: Lubricate the new front seal with clean engine oil. Using the special tools, install a new crankshaft front seal. 2. Install the crankshaft pulley. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Valve Seals Special Tools Material Removal 1. Remove the valve springs. 2. Remove the valve seals. Installation 1. NOTE: Lubricate the valve seals with clean engine oil. Using the special tool, install the valve seal. 2. Install the valve springs. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations View 151-1 (Engine Compartment - 4.0L, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 2192 C103 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Description and Operation Oil Temperature Sensor/Switch: Description and Operation ENGINE OIL TEMPERATURE (EOT) SENSOR Typical EOT Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance changes 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 EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system. The PCM can use the EOT sensor input to determine the following: - On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM begins reducing power by disabling engine cylinders. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications Timing Chain Tensioner: Specifications Hydraulic Chain Tensioner Tighten to ............................................................................................................................................. ................................................ 44 Nm (32 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 2200 Timing Chain Tensioner: Diagrams Valve Train Components - Exploded View Valve Train Components - Exploded View (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 2201 Valve Train Components - Exploded View (Part 2) Valve Train Components - Exploded View (Part 3) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 2202 Valve Train Components - Exploded View (Part 4) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Timing Drive Components - Hydraulic Chain Tensioner, RH Timing Chain Tensioner: Service and Repair Timing Drive Components - Hydraulic Chain Tensioner, RH Hydraulic Timing Chain Tensioner - RH Material Removal and Installation 1. Remove the hydraulic chain tensioner. ^ To install, tighten to 44 Nm (32 ft. lbs.). 2. Remove and discard the washer. 3. To install, reverse the removal procedure. ^ Install a new hydraulic chain tensioner washer. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Timing Drive Components - Hydraulic Chain Tensioner, RH > Page 2205 Timing Chain Tensioner: Service and Repair Timing Drive Components - Hydraulic Chain Tensioner, LH Hydraulic Timing Chain Tensioner - LH Material Removal and Installation 1. Remove the hydraulic chain tensioner. ^ To install, tighten to 44 Nm (32 ft. lbs.). 2. Remove and discard the washer 3. To install, reverse the removal procedure. ^ Install a new hydraulic chain tensioner washer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Engine front cover bolts ....................................................................................................................... ..................................................... 19 Nm (14 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2209 Timing Cover: Service and Repair Engine Front Cover Material Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2210 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2211 Removal 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Drain the cooling system. For additional information, refer to Cooling System. 3. Remove the crankshaft front seal. 4. Remove the nut and detach the wiring harness bracket from the front cover. 5. Remove the 5 oil pan-to-front cover bolts. 6. Disconnect the lower radiator hose. 7. Remove the bolt and the drive belt tensioner. 8. Disconnect the heater hose from the coolant pump. 9. Disconnect the crankshaft position (CKP) sensor electrical connector. 10. Disconnect the generator electrical connectors and the wiring harness retainer. 11. Remove the 3 generator bracket bolts and the generator bracket. 12. Remove the coil bracket-to-LH accessory drive bracket bolt. 13. Remove the 4 bolts and the LH accessory drive bracket. 14. Remove and discard the CKP sensor wiring harness retainers. 15. Disconnect the engine coolant temperature (ECT) sensor electrical connector. 16. Disconnect the upper radiator hose from the thermostat housing. 17. Disconnect the heater hose from the thermostat housing. 18. NOTE: The bypass hose will be removed with the thermostat housing. Release the bypass hose clamp from the coolant pump end. 19. Remove the 3 bolts and the thermostat housing. 20. NOTE: Note the positions of the stud bolts for installation reference. Remove the 10 bolts, the engine front cover and the gasket. Discard the gasket. Installation 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of the old front cover gasket and the silicone sealer. Clean and inspect the gasket mating surfaces. Use silicone gasket remover and metal surface prep and a plastic scraping tool. Follow the directions on the packaging. 2. Position the front cover gasket. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2212 CAUTION: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage. 3. Apply silicone gasket and sealant to the oil pan and engine block mating surfaces. 4. Apply silicone gasket and sealant to the front cover in 2 places. 5. NOTE: Make sure the stud bolts are installed in their original positions. Position the engine front cover and install the 10 bolts. ^ Tighten to 19 Nm (14 ft. lbs.). 6. NOTE: Make sure the coolant bypass hose is attached to the coolant pump. Position the thermostat housing and install the 3 bolts. ^ Tighten to 11 Nm (8 ft. lbs.). 7. Position the bypass hose clamp. 8. Connect the upper radiator hose to the thermostat housing. 9. Connect the heater hose to the thermostat housing. 10. Connect the ECT sensor electrical connector. 11. Install new wiring harness retainers and position the CKP sensor wiring. 12. Connect the CKP sensor electrical connector. 13. Position the LH accessory drive bracket and install the 4 bolts. ^ Tighten to 42 Nm (31 ft. lbs.). 14. Install the ignition coil bracket-to-LH accessory drive bracket bolt. ^ Tighten to 10 Nm (89 inch lbs.). 15. Position the generator bracket and install the 3 bolts. ^ Tighten to 42 Nm (31 ft. lbs.). 16. Connect the generator electrical connectors and the wiring harness retainer. ^ Tighten to 9 Nm (80 inch lbs.). 17. Connect the heater hose to the coolant pump. 18. Position the accessory drive belt tensioner and install the bolt. ^ Tighten to 47 Nm (35 ft. lbs.). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2213 19. Connect the lower radiator hose. 20. NOTE: The 5 bolts may or may not have washers. All the bolts should be of the same type. Install the 5 cylinder block cradle-to-front cover bolts. ^ Tighten bolts with washers to 10 Nm (89 inch lbs.). ^ Tighten bolts without washers to 14 Nm (10 ft. lbs.). 21. Position the wiring harness bracket and install the nut. ^ Tighten to 20 Nm (15 ft. lbs.). 22. Install the crankshaft front seal. 23. Connect the battery ground cable. For additional information, refer to Battery. 24. Fill the engine cooling system For additional information, refer to Cooling system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 C1451 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 > Page 2219 C1452 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Page 2220 Variable Valve Timing Actuator: Description and Operation VARIABLE CAMSHAFT TIMING (VCT) SYSTEM Overview The VCT enables rotation of the camshaft(s) relative to the crankshaft rotation as a function of engine operating conditions. There are 4 types of VCT systems. Exhaust phase shifting (EPS) system - the exhaust cam is the active cam being retarded. - Intake phase shifting (IPS) system - the intake cam is the active cam being advanced. - Dual equal phase shifting (DEPS) system - both intake and exhaust cams are phase shifted and equally advanced or retarded. - Dual independent phase shifting (DIPS) system - where both the intake and exhaust cams are shifted independently. All systems have 4 operational modes: idle, part throttle, wide open throttle (WOT), and default mode. At idle and low engine speeds with closed throttle, the powertrain control module (PCM) determines the phase angle based on air flow, engine oil temperature and engine coolant temperature. At part and wide open throttle the PCM determines the phase angle based on engine RPM, load, and throttle position. VCT systems provide reduced emissions and enhanced engine power, fuel economy and idle quality. IPS systems also have the added benefit of improved torque. In addition, some VCT system applications can eliminate the need for an external exhaust gas recirculation (EGR) system. The elimination of the EGR system is accomplished by controlling the overlap time between the intake valve opening and exhaust valve closing. Currently, both the IPS and DEPS systems are used. Variable Camshaft Timing (VCT) System VCT System The VCT system consists of an electric hydraulic positioning control solenoid, a camshaft position (CMP) sensor, and a trigger wheel. The CMP trigger wheel has a number of equally spaced teeth equal to the number (n) of cylinders on a bank plus one extra tooth (n+1). Four cylinder and V8 engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1 tooth trigger wheel. The extra tooth placed between the equally spaced teeth represents the CMP signal for that bank. A crankshaft position sensor (CKP) provides the PCM with crankshaft positioning information in 10 degree increments. 1. The PCM receives input signals from the intake air temperature (IAT) sensor, engine coolant temperature (ECT) sensor, engine oil temperature (EOT) sensor, CMP, throttle position (TP) sensor, mass air flow (MAF) sensor, and CKP to determine the operating conditions of the engine. At idle and low engine speeds with closed throttle, the PCM controls the camshaft position based on ECT, EOT, IAT, and MAF. During part and wide open throttle, the camshaft position is determined by engine RPM, load and throttle position. The VCT system does not operate until the engine is at normal operating temperature. 2. The VCT system is enabled by the PCM when the correct conditions are met. 3. The CKP signal is used as a reference for CMP positioning. 4. The VCT solenoid valve is an integral part of the VCT system. The solenoid valve controls the flow of engine oil in the VCT actuator assembly. As the PCM controls the duty cycle of the solenoid valve, oil pressure/flow advances or retards the cam timing. Duty cycles near 0% or 100% represent rapid movement of the camshaft. Retaining a fixed camshaft position is accomplished by dithering (oscillating) the solenoid valve duty cycle. The PCM calculates and determines the desired camshaft position. It continually updates the VCT solenoid duty cycle until the desired position is achieved. A difference between the desired and actual camshaft position represents a position error in the PCM VCT control loop. The PCM disables the VCT and places the camshaft in a default position if a concern is detected. A related DTC is also set when the concern is detected. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Diagrams > Page 2221 5. When the VCT solenoid is energized, engine oil is allowed to flow to the VCT actuator assembly which advances or retards the camshaft timing. One half of the VCT actuator is coupled to the camshaft and the other half is connected to the timing chain. Oil chambers between the 2 halves couple the camshaft to the timing chain. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the camshaft to rotate in either an advance or retard position depending on the oil flow. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Service and Repair Variable Valve Timing Solenoid: Service and Repair VARIABLE CAMSHAFT TIMING (VCT) OIL CONTROL SOLENOID Removal and Installation 1. Remove the valve cover. 2. Remove the bolt and the VCT oil control solenoid. - To install, tighten to 5 Nm (44 lb-in). 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Item....................................................................................................................................................... ..............................................................Specification Fuel Pressure Key on, engine off................................................................................................................................. .............................................207-276 kPa (30-40 psi) Engine running................................................. ..................................................................................................................................207-276 kPa (30-40 psi) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Hot Idle Speed ..................................................................................................................................... ............................................................ 750-820 RPM Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair AIR CLEANER ELEMENT Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 2236 Exploded View Removal and Installation NOTE: Do not disconnect the mass air flow (MAF) sensor electrical connector. Vehicles equipped with a 4.0L (SOHC) engine 1. Detach the wiring harness retainer from the air cleaner outlet pipe. Vehicles equipped with a 4.6L (3V) engine Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 2237 2. Detach the wiring harness retainer from the coolant expansion tank. All vehicles 3. Loosen the clamp and disconnect the air cleaner outlet pipe from the air cleaner. 4. Unclip and remove the air cleaner cover. 5. Remove the air cleaner element. 6. NOTE: Clean the inside of the air cleaner tray. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE 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. - 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, which can cause a fire hazard. Failure to follow these instructions may result in personal injury. 1. NOTE: The front passenger door frame scuff plate is retained only by internal metal clips. Remove the front passenger door frame scuff plate. 2. NOTE: - The front passenger door side interior kick panel is retained only by internal metal clips. - It may be necessary to reposition the lower end of the door jam weather stripping to remove the front passenger door side interior kick panel. Remove the front passenger side interior kick panel. 3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Start the engine and allow it to idle until it stalls. 5. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail pressure has been released. 6. Turn the ignition switch to the OFF position. 7. When the fuel system service is complete, reconnect the IFS switch electrical connector. 8. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 9. Start the vehicle and check the fuel system for leaks. 10. Install the front passenger side interior kick panel. 11. Install the front passenger door frame scuff plate. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Item....................................................................................................................................................... ..............................................................Specification Firing order........................................................................................................................................... ..................................................................1-4-2-5-3-6 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > System Information > Specifications Ignition Timing: Specifications Item....................................................................................................................................................... ..............................................................Specification Base ignition timing.............................................................................................................................. ..............................10 degrees BTDC Non-adjustable Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair Ignition Cable: Service and Repair SPARK PLUG WIRES Exploded View Special Tool(s) Special Tool(s) Removal and Installation 1. CAUTION: It is important to twist the spark plug wire boot while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Page 2251 Squeeze the locking tabs and twist while pulling upward to disconnect the 6 spark plug wires from the ignition coil. 2. Detach the spark plug wires from the spark plug wire retainers. 3. CAUTION: It is important to twist the spark plug wire boot while pulling upward to avoid damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct spark plug. With a twisting motion, use the special tool to pull the spark plug wires from the spark plugs. 4. NOTE: Apply silicone dielectric compound to the inside of the spark plug wire boots. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > General Specifications Spark Plug: Specifications General Specifications Item....................................................................................................................................................... ..............................................................Specification Spark plug gap..................................................................................................................................... ....................................1.32-1.42 mm (0.052-0.056 in) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > General Specifications > Page 2256 Torque Specifications Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2257 Spark Plug: Application and ID SPARK PLUG TYPE LH ........................................................................................................................................................ .......................................................... AGSF24PM RH ....................................................................................................................................................... ........................................................ AGSF24PGM Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2258 Spark Plug: Testing and Inspection Spark Plug Inspection 1. Inspect the spark plug for a bridged gap. ^ Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or carbon fouling. ^ Clean the spark plug. 2. Check for oil fouling. ^ Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil entering the combustion chamber through worn rings and pistons, excessive valve-to-guide clearance or worn or loose bearings. ^ Correct the oil leak concern. ^ Install a new spark plug. 3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips, exposed shell surfaces and electrodes, caused by a spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive idling. ^ Clean the spark plug. 4. Inspect for normal burning. ^ Check for light tan or gray deposits on the firing tip. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2259 5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator. Metallic deposits on the insulator indicate engine damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized installation of a heli-coil insert in place of the spark plug threads. ^ Install a new spark plug. 6. Inspect for overheating, identified by white or light gray spots and with bluish-burnt appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing. ^ Install a new spark plug. 7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. ^ Clean the spark plug. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2260 Spark Plug: Service and Repair SPARK PLUGS Exploded View Special Tool(s) Removal and Installation Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2261 1. CAUTION: It is important to twist the spark plug wire boot while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct spark plug. With a twisting motion, use the special tool to pull the spark plug wire from the spark plug. 2. NOTE: Use compressed air to remove any foreign material from the spark plug wells before removing the spark plugs Remove the spark plugs. To install, tighten to 17 Nm (13 lb-ft). 3. Use a suitable spark plug gap tool to check and adjust the spark plug gap. 4. NOTE: Apply silicone dielectric compound to the inside of the spark plug wire boots. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 at least 75% of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Compression Pressure Limit Chart Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2265 Compression Check: Testing and Inspection Compression Test - Compression Gauge Check 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 5 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 at least 75% of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Compression Pressure Limit Chart If one or more cylinders read low, squirt approximately one tablespoon of engine oil 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. 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If 2 adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2266 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 at least 75% of the highest reading. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Coolant pump bolts .............................................................................................................................. ................................................. 10 Nm (89 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2270 Water Pump: Service and Repair Coolant Pump - 4.0L SOHC Material Removal and Installation 1. Drain the engine cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding. 2. Remove the cooling fan. 3. Remove the accessory drive belt. 4. Remove the bolts and the coolant pump pulley. ^ To install, tighten to 25 Nm (18 ft. lbs.). 5. Release the clamp and disconnect the coolant pump bypass hose. 6. Release the clamp and disconnect the heater hose. 7. Release the clamp and disconnect the lower radiator hose. 8. Remove the bolts, the coolant pump and the gasket. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2271 ^ To install, tighten to 10 Nm (89 inch lbs.). 9. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of the old gasket. Clean the mating surfaces with a plastic scraper and metal surface prep. Follow the directions on the packaging. 10. To install, reverse the removal procedure. ^ Install a new coolant pump gasket. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity: Without auxiliary climate control ............................................................................................................................................................ 12.2 qts (11.5L) With auxiliary climate control ............................................................................................................... .................................................. 13.9 qts (13.2L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 2277 Coolant: Fluid Type Specifications Engine Coolant .............................................................................................................................................. Motorcraft Premium Gold Engine Coolant VC-7-A ................................................................................................................................................. ............................... US except CA, OR and NM VC-7-B ................................................................................................................................................. ................................................. CA, OR and NM Note: Add the coolant type originally equipped in your vehicle. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair Coolant Line/Hose: Service and Repair Coolant Crossover Manifold Assembly Coolant Crossover Manifold Assembly (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Page 2281 Coolant Crossover Manifold Assembly (Part 2) Removal and Installation 1. Disconnect the battery ground cable. 2. Drain the engine cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding. 3. Remove the intake manifold. 4. Rotate the accessory drive belt tensioner clockwise and detach the belt from the generator pulley. 5. Disconnect the electrical connector. 6. Loosen the generator nuts. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Page 2282 ^ To install, tighten to 25 Nm (18 ft. lbs.). 7. Remove the generator bracket-to-coolant crossover bolts, and position the generator, bracket and wiring harness aside as an assembly. ^ To install, tighten to 10 Nm (89 inch lbs.). 8. Disconnect the PCV heater hose from the coolant crossover manifold assembly. 9. Disconnect the heater hose from the coolant crossover manifold assembly. 10. Disconnect the upper radiator hose from the coolant crossover manifold assembly. 11. Remove the bolts, the coolant crossover manifold assembly and the gaskets. Discard the gaskets. ^ To install, tighten to 10 Nm (89 inch lbs.). 12. To install, reverse the removal procedure. ^ Install new gaskets. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Coolant Reservoir: > 09-11-12 > Jun > 09 > Cooling System - Coolant Leaks From The Reservoir Coolant Reservoir: Customer Interest Cooling System - Coolant Leaks From The Reservoir TSB 09-11-12 06/15/09 COOLANT EXPANSION TANK LEAKS - 4.0L ENGINE FORD: 2006-2009 Explorer 2007-2009 Explorer Sport Trac MERCURY: 2006-2009 Mountaineer ISSUE Some 2006-2009 Explorer, Mountaineer and 2007-2009 Explorer Sport Trac vehicles equipped with 4.0L engine may experience coolant leaking from the coolant expansion tank. This may be due to cracks that develop in the coolant expansion tank at the radiator mounting bolt locations. ACTION Replace the coolant expansion tank. Follow the service procedure steps to correct the condition. SERVICE PROCEDURE 1. Allow the engine to cool before removing the coolant expansion tank. 2. Disconnect the coolant overflow hose. 3. Remove the bolts and the coolant expansion tank. (Figure 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Coolant Reservoir: > 09-11-12 > Jun > 09 > Cooling System - Coolant Leaks From The Reservoir > Page 2291 4. Make sure the J clips in the upper radiator mounting boss sit flush. (Figure 2) 5. Install the updated coolant expansion tank. 6. Use the new bolt fasteners. 7. Torque to 43 lb-in (4.8 N.m). 8. Connect the coolant overflow hose. 9. Verify proper coolant level. Parts Block 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 091112A 2006-2009 Explorer, 0.4 Hr. Mountaineer, 2007-2009 Explorer Sport Trac: Replace Coolant Expansion Tank(Do Not Use With 8080A) DEALER CODING CONDITION BASIC PART NO. CODE 8A080 01 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Reservoir: > 09-11-12 > Jun > 09 > Cooling System - Coolant Leaks From The Reservoir Coolant Reservoir: All Technical Service Bulletins Cooling System - Coolant Leaks From The Reservoir TSB 09-11-12 06/15/09 COOLANT EXPANSION TANK LEAKS - 4.0L ENGINE FORD: 2006-2009 Explorer 2007-2009 Explorer Sport Trac MERCURY: 2006-2009 Mountaineer ISSUE Some 2006-2009 Explorer, Mountaineer and 2007-2009 Explorer Sport Trac vehicles equipped with 4.0L engine may experience coolant leaking from the coolant expansion tank. This may be due to cracks that develop in the coolant expansion tank at the radiator mounting bolt locations. ACTION Replace the coolant expansion tank. Follow the service procedure steps to correct the condition. SERVICE PROCEDURE 1. Allow the engine to cool before removing the coolant expansion tank. 2. Disconnect the coolant overflow hose. 3. Remove the bolts and the coolant expansion tank. (Figure 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Reservoir: > 09-11-12 > Jun > 09 > Cooling System - Coolant Leaks From The Reservoir > Page 2297 4. Make sure the J clips in the upper radiator mounting boss sit flush. (Figure 2) 5. Install the updated coolant expansion tank. 6. Use the new bolt fasteners. 7. Torque to 43 lb-in (4.8 N.m). 8. Connect the coolant overflow hose. 9. Verify proper coolant level. Parts Block 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 091112A 2006-2009 Explorer, 0.4 Hr. Mountaineer, 2007-2009 Explorer Sport Trac: Replace Coolant Expansion Tank(Do Not Use With 8080A) DEALER CODING CONDITION BASIC PART NO. CODE 8A080 01 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Technical Service Bulletins > Page 2298 Coolant Reservoir: Service and Repair Coolant Expansion Tank Material Material CAUTION: Allow the engine to cool before removing the coolant expansion tank. The radiator draws coolant from the coolant expansion tank as the engine cools. If the coolant expansion tank is removed before the engine cools, the radiator will draw air into the system, resulting in possible engine damage. 1. Disconnect the coolant overflow hose. 2. If equipped, detach the mass air flow (MAF) sensor wiring harness retainer. 3. Remove the bolts and the coolant expansion tank. ^ To install, tighten to 7 Nm (62 inch lbs.). 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Technical Service Bulletins > Page 2299 ^ Fill the coolant expansion tank with a 50/50 mixture of coolant and clean, drinkable water. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Description and Operation Radiator Cooling Fan Motor: Description and Operation FAN CONTROL The PCM monitors certain parameters (such as engine coolant temperature, vehicle speed, A/C on/off status, A/C pressure) to determine engine cooling fan needs. For variable speed electric fan(s): Edge/MKX, Five Hundred/Freestyle/Montego, Fusion/Milan/MKZ, Crown Victoria/Grand Marquis, Town Car: FCV Duty Cycle Output From PCM (Negative Duty Cycle) The PCM controls the fan speed and operation using a duty cycle output on the fan control variable (FCV) circuit. The fan controller (located at or integral to the engine cooling fan assembly) receives the FCV command and operates the cooling fan at the speed requested (by varying the power applied to the fan motor). For relay controlled fans: 2.0L Focus (with A/C) And Taurus: PCM FC Output State For Cooling Fan Speeds 2.3L Escape: PCM FC Output State For Cooling Fan Speeds Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Description and Operation > Page 2304 Freestar, Monterey: PCM FC Output State For Cooling Fan Speeds The PCM controls the fan operation through the fan control (FC) (single speed fan applications), low fan control (LFC), medium fan control (MFC), and/or high fan control (HFC) outputs. Some applications will have the xFC circuit wired to 2 separate relays. For 3-speed fans, although the PCM output circuits are called low, medium, and high fan control (FC), cooling fan speed is controlled by a combination of these outputs. Refer to the table. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Speed Sensor > Component Information > Description and Operation Radiator Cooling Fan Speed Sensor: Description and Operation FAN SPEED SENSOR (FSS) Cooling Fan Clutch With (FSS) The FSS is a Hall-effect sensor that measures the cooling fan clutch speed by generating a waveform with a frequency proportional to the fan speed. If the cooling fan clutch is moving at a relatively low speed, the sensor produces a signal with a low frequency. As the cooling fan clutch speed increases, the sensor generates a signal with a higher frequency. The powertrain control module (PCM) uses the frequency signal generated by the FSS as a feedback for closed loop control of the cooling fan clutch. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Service and Repair Fan Blade: Service and Repair Cooling Fan Special Tools Removal and Installation Vehicle equipped with a 4.6L (3V) 1. Remove the air cleaner outlet pipe. All vehicles 2. Remove the coolant expansion tank. 3. Remove the bolt and position the power steering fluid reservoir aside. ^ To install, tighten to 10 Nm (89 inch lbs.). 4. Remove the bolts, then unclip the upper fan shroud from the lower fan shroud and remove the upper fan shroud. ^ To install, tighten to 7 Nm (62 inch lbs.). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Service and Repair > Page 2311 5. Disconnect the fan clutch electrical connector. 6. Remove the fan clutch wiring harness bracket bolt. ^ To install, tighten to 7 Nm (62 inch lbs.). 7. Using the special tools, remove the cooling fan. ^ To install, tighten to 55 Nm (41 ft. lbs.). 8. Remove the bolts and separate the fan from the fan clutch. ^ To install, tighten to 7 Nm (62 inch lbs.). 9. If necessary, unclip and disconnect the fan clutch wiring harness. 10. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Diagrams C1158 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Diagrams > Page 2315 Fan Clutch: Description and Operation COOLING FAN CLUTCH Cooling Fan Clutch With Fan Speed Sensor (FSS) The cooling fan clutch is an electrically actuated viscous clutch that consists of 3 main elements: - a working chamber - a reservoir chamber - a cooling fan clutch actuator valve and a fan speed sensor (FSS) The cooling fan clutch actuator valve controls the fluid flow from the reservoir into the working chamber. Once viscous fluid is in the working chamber, shearing of the fluid results in fan rotation. The cooling fan clutch actuator valve is activated with a pulse width modulated (PWM) output signal from the PCM. By opening and closing the fluid port valve, the PCM can control the cooling fan clutch speed. The cooling fan clutch speed is measured by a Hall-effect sensor and is monitored by the PCM during closed loop operation. The PCM optimizes fan speed based on engine coolant temperature (ECT), engine oil temperature (EOT), transmission fluid temperature (TFT), intake air temperature (IAT), or air conditioning requirements. When an increased demand for fan speed is requested for vehicle cooling, the PCM monitors the fan speed through the Hall-effect sensor. If a fan speed increase is required, the PCM outputs the PWM signal to the fluid port, providing the required fan speed increase. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Diagrams > Page 2316 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2321 C1064 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2322 Coolant Temperature Sensor/Switch (For Computer): Description and Operation ENGINE COOLANT TEMPERATURE (ECT) SENSOR Typical Thread Type ECT Sensor The ECT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance changes 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 PCM uses the ECT input for fuel control and for cooling fan control. There are 3 types of ECT sensors, threaded, push-in, and twist-lock. The ECT sensor is located in an engine coolant passage. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2323 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR Removal and Installation 1. Drain the cooling system. 2. Disconnect the engine coolant temperature (ECT) sensor electrical connector. 3. Remove the clip and the ECT sensor. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Diagrams C107 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Diagrams > Page 2327 Engine Temperature Sensor: Description and Operation CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical CHT Sensor The CHT sensor is a thermistor device in which resistance changes with the temperature. The electrical resistance of a thermistor decreases as temperature increases., and the resistance 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. The CHT sensor is installed in the 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 initiates a fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern 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. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair Fan Shroud: Service and Repair Cooling Fan Shroud Special Tools Removal and Installation Vehicles equipped with a 4.6L (3V) engine 1. Remove the air cleaner outlet pipe. All vehicles 2. Remove the coolant expansion tank. 3. Remove the bolt and position the power steering fluid reservoir aside. ^ To install, tighten to 10 Nm (89 inch lbs.). 4. Remove the bolts, then unclip the upper fan shroud from the lower fan shroud and remove the upper fan shroud. ^ To install, tighten to 7 Nm (62 inch lbs.). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Page 2331 5. Disconnect the fan clutch electrical connector. 6. Remove the fan clutch wiring harness bracket bolt. ^ To install, tighten to 7 Nm (62 inch lbs.). 7. Using the special tools, remove the cooling fan. ^ To install, tighten to 55 Nm (41 ft. lbs.). 8. Remove the bolts and the lower fan shroud. ^ To install, tighten to 7 Nm (62 inch lbs.). 9. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Component Information > Service and Repair Heater Control Valve: Service and Repair HEATER CONTROL VALVE Removal and Installation Vehicles with 4.0L and oil cooler, without auxiliary climate control 1. With the vehicle in NEUTRAL, position it on a hoist. All vehicles 2. Drain the engine coolant. 3. Disconnect the 2 inlet and outlet heater hose clamps. 4. Disconnect the heater control valve vacuum hose. Vehicles with 4.0L and oil cooler, without auxiliary climate control 5. Remove the heater control valve bolt. All vehicles 6. Remove the heater control valve. 7. NOTE: Lubricate the coolant hoses with plain water only if needed. To install, reverse the removal procedure. 8. Fill the engine cooling system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 (V6-4.0L VIN K (2007)) 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 2343 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 (V6-4.0L VIN K (2007)) 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 2344 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 (V6-4.0L VIN K (2007)) 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 (V6-4.0L VIN K (2007)) 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 2350 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 (V6-4.0L VIN K (2007)) 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 2351 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core Heater Core: Service and Repair Heater Core HEATER CORE Removal and Installation NOTE: If a heater core leak is suspected, the heater core must be pressure leak tested before it is removed from the vehicle. 1. Remove the heater core and evaporator core housing. 2. Remove the 2 LH floor duct screws. 3. Remove the LH floor duct. 4. Remove the 2 RH floor duct screws. 5. Remove the RH floor duct. 6. Remove the 3 housing brace screws. 7. Remove the housing brace. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core > Page 2354 8. Remove the 3 heater tube cover screws. 9. Remove the heater tube cover. 10. Remove the heater tube seal. 11. Remove the 4 heater core cover screws. 12. Remove the heater core cover. 13. Remove the heater core. 14. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core > Page 2355 Heater Core: Service and Repair Auxiliary Heater Core AUXILIARY HEATER CORE Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core > Page 2356 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine coolant. 3. Release the 2 heater hose clamps and disconnect the heater hoses. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core > Page 2357 4. Remove the rear quarter trim panel. 5. Remove the 2 auxiliary line floorpan bracket nuts. 6. NOTE: The screw and line bracket are located inside the vehicle above the floorpan line bracket. Remove the 4 line bracket screws and the line bracket. 7. Disconnect the auxiliary harness electrical connector. 8. Remove the 2 auxiliary housing bolts and auxiliary housing nut. - To install, tighten to 6 Nm (53 lb-in). 9. Disconnect the 2 auxiliary actuator electrical connectors. 10. Remove the 3 auxiliary mode door actuator screws. 11. Remove the auxiliary mode door actuator. 12. Remove the 3 auxiliary temperature blend door actuator screws. 13. Remove the auxiliary temperature blend door actuator. 14. Remove the 4 heater core cover screws. 15. Remove the heater core cover. 16. Disconnect the 2 heater core hose clamps. 17. Remove the auxiliary heater core. 18. To install, reverse the removal procedure. - Lubricate the coolant hoses with plain water only if needed. 19. Fill the engine cooling system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 (V6-4.0L VIN K (2007)) 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 2366 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 (V6-4.0L VIN K (2007)) 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 2367 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 (V6-4.0L VIN K (2007)) 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 (V6-4.0L VIN K (2007)) 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 2373 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 (V6-4.0L VIN K (2007)) 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 2374 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxiliary Heater Outlet and Inlet Line - Front Heater Hose: Service and Repair Auxiliary Heater Outlet and Inlet Line - Front AUXILIARY HEATER OUTLET AND INLET LINE - FRONT Removal and Installation 1. Remove the RH running board. 2. Drain the engine coolant. 3. Remove the RH rear wheel. 4. Release the front auxiliary heater line front clamps and disconnect the heater hoses. 5. Release the front auxiliary heater line rear clamps and disconnect the heater hoses. 6. Remove the 3 auxiliary line bracket nuts. - To install, tighten to 6 Nm (53 lb-in). 7. Remove the 3 auxiliary line bracket bolts. - To install, tighten to 6 Nm (53 lb-in). 8. Remove the 6 auxiliary line brackets. 9. Remove the front auxiliary heater outlet and inlet lines. 10. To install, reverse the removal procedure. 11. Fill the engine cooling system, Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxiliary Heater Outlet and Inlet Line - Front > Page 2377 Heater Hose: Service and Repair Auxiliary Heater Outlet and Inlet Line - Rear AUXILIARY HEATER OUTLET AND INLET LINE - REAR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine coolant. 3. Remove the spare tire. 4. Remove the 4 spare tire carrier bolts and the 2 spare tire carrier shield pin-type retainers. 5. Remove the spare tire carrier. 6. Release the 2 rear auxiliary heater line front hose clamps and disconnect the hoses. 7. Release the 2 rear auxiliary heater line rear hose clamps and disconnect the hoses. 8. Remove the 2 auxiliary line bracket nuts. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxiliary Heater Outlet and Inlet Line - Front > Page 2378 - To install, tighten to 8 Nm (71 lb-in). 9. Remove the 2 auxiliary line brackets. 10. Remove the rear auxiliary heater outlet line. 11. Remove the rear auxiliary heater inlet line. 12. To install, reverse the removal procedure. 13. Fill the engine cooling system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair Radiator: Service and Repair Radiator Special Tools Removal and Installation All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair 2. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding. Vehicles equipped with a 4.6L engine 3. Remove the air cleaner outlet pipe. All vehicles 4. Remove the coolant expansion tank. 5. Remove the bolt and position the power steering fluid reservoir aside. ^ To install, tighten to 10 Nm (89 inch lbs.). 6. Release the clamp and disconnect the upper radiator hose. 7. Release the clamp and disconnect the lower radiator hose. 8. Detach the lower radiator hose retainer from the lower fan shroud. 9. Detach the transmission cooler hose retainer from the RH radiator support bracket. 10. Remove the 4 lower radiator air deflector pushpins. 11. Remove the latch assemblies from the transmission cooler tubes. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Page 2382 12. Using the special tool, disconnect the transmission cooler tubes. 13. Remove the upper fan shroud bolts, then unclip the upper fan shroud from the lower fan shroud and remove the upper fan shroud. ^ To install, tighten to 7 Nm (62 inch lbs.). 14. Disconnect the fan clutch electrical connector. 15. Remove the fan clutch wiring harness bracket bolt. ^ To install, tighten to 7 Nm (62 inch lbs.). 16. NOTE: 4.6L (3V) engine shown, 4.0L SOHC engine similar. Using the special tools, remove the cooling fan. ^ To install, tighten to 55 Nm (41 ft. lbs.). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Page 2383 17. Remove the bolts and the lower fan shroud. 18. NOTE: 4.6L (3V) engine shown, 4.0L SOHC similar. Detach the A/C tube from the retainer. 19. Remove the radiator support bracket-to-radiator support bolts. ^ To install, tighten to 15 Nm (11 ft. lbs.). 20. Remove the radiator top seal. 21. NOTE: Do not remove the A/C condenser seals. Deflect the A/C condenser seals and remove the A/C condenser-to-radiator support bracket bolts. ^ Position the A/C condenser aside. ^ To install, tighten to 12 Nm (9 ft. lbs.). 22. Remove the radiator and the radiator support brackets as an assembly. 23. Remove the bolts and separate the radiator support brackets and the radiator. ^ To install, tighten to 12 Nm (9 ft. lbs.). 24. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Radiator Cooling Fan Speed Sensor > Component Information > Description and Operation Radiator Cooling Fan Speed Sensor: Description and Operation FAN SPEED SENSOR (FSS) Cooling Fan Clutch With (FSS) The FSS is a Hall-effect sensor that measures the cooling fan clutch speed by generating a waveform with a frequency proportional to the fan speed. If the cooling fan clutch is moving at a relatively low speed, the sensor produces a signal with a low frequency. As the cooling fan clutch speed increases, the sensor generates a signal with a higher frequency. The powertrain control module (PCM) uses the frequency signal generated by the FSS as a feedback for closed loop control of the cooling fan clutch. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Locations > Page 2392 C1064 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Locations > Page 2393 Coolant Temperature Sensor/Switch (For Computer): Description and Operation ENGINE COOLANT TEMPERATURE (ECT) SENSOR Typical Thread Type ECT Sensor The ECT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance changes 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 PCM uses the ECT input for fuel control and for cooling fan control. There are 3 types of ECT sensors, threaded, push-in, and twist-lock. The ECT sensor is located in an engine coolant passage. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Locations > Page 2394 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR Removal and Installation 1. Drain the cooling system. 2. Disconnect the engine coolant temperature (ECT) sensor electrical connector. 3. Remove the clip and the ECT sensor. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Diagrams C107 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Diagrams > Page 2398 Engine Temperature Sensor: Description and Operation CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical CHT Sensor The CHT sensor is a thermistor device in which resistance changes with the temperature. The electrical resistance of a thermistor decreases as temperature increases., and the resistance 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. The CHT sensor is installed in the 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 initiates a fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern 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. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Thermostat Opening Temperature Starts to open ...................................................................................................................................... ............................................. 90-94°C (194-201°F) Fully open ........................................................... ........................................................................................................................................ 106°C (223°F) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2402 Thermostat: Diagrams Thermostat and Thermostat Housing - Exploded View, 4.0L SOHC Thermostat And Thermostat Housing-Exploded View, 4.0L SOHC (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2403 Thermostat And Thermostat Housing-Exploded View, 4.0L SOHC (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2404 Thermostat: Service and Repair Thermostat - 4.0L SOHC Removal and Installation 1. Drain the engine cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding. 2. Release the clamp and disconnect the upper radiator hose from the thermostat housing cover. 3. Remove the bolts and the thermostat housing cover. ^ To install, tighten to 10 Nm (89 inch lbs.). 4. Remove the thermostat. 5. NOTE: Inspect the thermostat housing cover O-ring seal. Install a new O-ring seal if necessary. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Diagrams Thermostat Housing: Diagrams Thermostat and Thermostat Housing - Exploded View, 4.0L SOHC Thermostat And Thermostat Housing-Exploded View, 4.0L SOHC (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Diagrams > Page 2408 Thermostat And Thermostat Housing-Exploded View, 4.0L SOHC (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Coolant pump bolts .............................................................................................................................. ................................................. 10 Nm (89 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2412 Water Pump: Service and Repair Coolant Pump - 4.0L SOHC Material Removal and Installation 1. Drain the engine cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding. 2. Remove the cooling fan. 3. Remove the accessory drive belt. 4. Remove the bolts and the coolant pump pulley. ^ To install, tighten to 25 Nm (18 ft. lbs.). 5. Release the clamp and disconnect the coolant pump bypass hose. 6. Release the clamp and disconnect the heater hose. 7. Release the clamp and disconnect the lower radiator hose. 8. Remove the bolts, the coolant pump and the gasket. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2413 ^ To install, tighten to 10 Nm (89 inch lbs.). 9. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of the old gasket. Clean the mating surfaces with a plastic scraper and metal surface prep. Follow the directions on the packaging. 10. To install, reverse the removal procedure. ^ Install a new coolant pump gasket. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation Catalytic Converter: Description and Operation CATALYST AND EXHAUST SYSTEMS Overview V-Engines In-Line Engines The catalytic converter and exhaust Systems 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). The major air pollutants of CO, NOx, and HCs, and their emission into the atmosphere must be controlled. The exhaust system generally consists of an exhaust manifold, front exhaust pipe, front heated oxygen sensor (HO2S), rear exhaust pipe, catalyst HO2S, a muffler, and an exhaust tailpipe. The catalytic converter is typically installed between the front and rear exhaust pipes. On some vehicle applications, more than one catalyst is used between the front and rear exhaust pipes. Catalytic converter efficiency is monitored by the on board diagnostic (OBD) system strategy in the PCM. For information on the OBD catalyst monitor, refer to the description for the Catalyst Efficiency Monitor. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes/Monitors/Catalyst Efficiency Monitor The number of HO2Ss used in the exhaust stream and the location of these sensors depend on the vehicle emission certification level (LEV, LEV-II, ULEV, PZEV). On most vehicles only 2 HO2Ss are used in an exhaust stream. The front sensors (HO2S11/HO2S21) before the catalyst are used for primary fuel control while the ones after the catalyst (HO2S12/HO2S22) are used to monitor catalyst efficiency. However, some partial zero emission vehicles (PZEV) use 3 HO2Ss for each engine bank. The stream 1 sensors (HO2S11/HO2S21) located before the catalyst are used for primary fuel control, the stream 2 sensors (HO2S12/HO2S22) are used to monitor the light-off catalyst, and the stream 3 sensors (HO2S13/HO2S23) located after the catalyst are used for long term fuel trim control to optimize catalyst efficiency (fore aft oxygen sensor control). Current PZEV vehicles use only a 4-cylinder engine, so only the bank 1 HO2Ss are used. Catalytic Converter Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 2418 A catalyst is a material that remains unchanged when it initiates and increases the speed of a chemical reaction. A catalyst also enables 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 ceramic 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. Light Off Catalyst As the catalyst heats up, converter efficiency rises rapidly. The point at which conversion efficiency exceeds 50% is called catalyst light off. For most catalysts this point occurs at 246°C to 302°C (475°F to 575°F). A fast light catalyst is a 3-way catalyst (TWC) that is located as close to the exhaust manifold as possible. Because the light off catalyst is located close to the exhaust manifold it lights off faster and reduces emissions more quickly than the catalyst located under the body. Once the catalyst lights off, the catalyst quickly reaches the maximum conversion efficiency for that catalyst. Three-Way Catalyst (TWC) Conversion Efficiency TWC Conversion Efficiency Chart A TWC requires a stoichiometric fuel ratio, 14.7 pounds of air to 1 pound of fuel (14.7:1), for high conversion efficiency. In order to achieve these high efficiencies, the air/fuel ratio must be tightly controlled with a narrow window of stoichiometry. Deviations outside of this window greatly decrease the conversion efficiency. For example a rich mixture decreases the HC and CO conversion efficiency while a lean mixture decreases the NOx conversion efficiency. Exhaust System Typical Bank 1 Catalyst 2 HO2S Configuration Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 2419 Typical Bank 1 Catalyst 3 HO2S Configuration 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. A HO2S is mounted on the front exhaust pipe before the catalyst. The catalytic converter reduces the concentration of CO, unburned HCs, and NOx in the exhaust emissions to an acceptable level. The reduced exhaust emissions are directed from the catalytic converter past another HO2S mounted in the rear exhaust pipe and then on into the muffler. Finally, the exhaust emissions are directed to the atmosphere through an exhaust tailpipe. On some PZEV, there is a total of 3 HO2S in the exhaust stream. One near the exhaust manifold (stream 1), one in the middle of the light-off catalyst (stream 2), and the third (stream 3) is mounted after the light-off catalyst. Underbody Catalyst The underbody catalyst is located after the light off catalyst. The underbody catalyst may be in line with the light off catalyst, or the underbody catalyst may be common to 2 light off catalysts, forming a Y pipe configuration. For an exact configuration of the catalyst and exhaust system for a specific vehicle, refer to Catalytic Converter, Exhaust System. Three-Way Catalytic (TWC) Converter The 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 NOx. The 3-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. 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. Heated Oxygen Sensor (HO2S) The HO2Ss provide the powertrain control module (PCM) with voltage and frequency information related to the oxygen content of the exhaust gas. 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 also reduces the noise produced by exhaust gases as they travel from the catalytic converter to the atmosphere. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust manifold nuts ......................................................................................................................... ..................................................... 22 Nm (16 ft. lbs.) Exhaust manifold studs .................................... ........................................................................................................................................... 12 Nm (9 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 2423 Exhaust Manifold: Testing and Inspection Exhaust Manifold Cleaning and Inspection Special Tool(s) 1. Clean the exhaust manifold using a suitable solvent. Use a plastic scraping tool to clean the gasket sealing surfaces. 2. NOTE: New exhaust manifold gaskets, studs, nuts and/or bolts must be installed when an exhaust manifold is serviced. Using the special tool (or a precision straight edge) and a feeler gauge, check the exhaust manifold sealing surface for warpage. If the warpage is greater than 0.76 mm (0.0299 inch), install a new exhaust manifold. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold - LH Exhaust Manifold: Service and Repair Exhaust Manifold - LH Exhaust Manifold - LH Exhaust Manifold-LH Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair 2. Remove the 4 exhaust manifold-to-dual converter Y-pipe nuts and position the dual converter Y-pipe aside. 3. Remove the 6 nuts, the LH exhaust manifold and the gasket. ^ Discard the nuts and the gasket. 4. Remove and discard the 6 LH exhaust manifold studs. Installation 1. Inspect the LH exhaust manifold gasket surfaces for flatness. 2. Install 6 new LH exhaust manifold studs. ^ Tighten to 12 Nm (9 ft. lbs.). 3. Position a new gasket, the LH exhaust manifold and install 6 new nuts. ^ Tighten to 22 Nm (16 ft. lbs.). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold - LH > Page 2426 4. Position the dual converter Y-pipe and install the 4 nuts. ^ Tighten to 40 Nm (30 ft. lbs.). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold - LH > Page 2427 Exhaust Manifold: Service and Repair Exhaust Manifold - RH Exhaust Manifold - RH Exhaust Manifold-RH Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair 2. Remove the exhaust gas recirculation (EGR) tube. 3. Remove the 4 exhaust manifold-to-dual converter Y-pipe nuts and position the dual converter Y-pipe aside. 4. Remove the 6 nuts, the RH exhaust manifold and the gasket. ^ Discard the nuts and the gasket. 5. Remove and discard the 6 RH exhaust manifold studs. Installation 1. Inspect the RH exhaust manifold gasket surfaces for flatness. 2. Install 6 new RH exhaust manifold studs. ^ Tighten to 12 Nm (9 ft. lbs.). 3. Position a new gasket, the RH exhaust manifold and install 6 new nuts. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold - LH > Page 2428 ^ Tighten to 22 Nm (16 ft. lbs.). 4. Position the dual converter Y-pipe and install the 4 nuts. ^ Tighten to 40 Nm (30 ft. lbs.). 5. Install the EGR tube. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Y-Pipe - Dual Catalytic Converter Exhaust Pipe: Service and Repair Exhaust Y-Pipe - Dual Catalytic Converter Exhaust Y-pipe - Dual Catalytic Converter Material Removal WARNING: The normal operating temperature of the exhaust system is very high. Never work around or attempt to repair any part of the exhaust system until it has cooled. Use special care when working around the catalytic converter. The catalytic converter heats to a high temperature after only a short period of engine operation. Failure to follow these instructions may result in personal injury. CAUTION: Do not use oil or grease-based lubricants on the isolators. These lubricants may cause deterioration of the rubber. This can lead to separation of the isolator from the exhaust hanger bracket during vehicle operation. Use only water-based lubricants on the isolators. NOTE: Exhaust fasteners are of a prevailing torque design. Use only new fasteners with the same part number as the original. Torque values must be used as specified during reassembly to make sure of correct retention of exhaust components. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair 2. Using a suitable jack, support the exhaust system. 3. Disconnect the heated oxygen sensor (HO2S) and the catalyst monitor sensors electrical connectors. 4. Remove the exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts, nuts and gasket. ^ Discard the exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts, nuts and gasket. 5. Remove the transmission support crossmember. 6. NOTE: RH side shown, LH similar. Remove the exhaust Y-pipe dual catalytic converter-to-exhaust manifold nuts. ^ Discard the exhaust Y-pipe dual catalytic converter-to-exhaust manifold nuts. 7. Remove the exhaust Y-pipe dual catalytic converter. Installation 1. NOTE: Apply anti-seize lubricant to the threads of the HO2S and catalyst monitor sensors. If removed, install the HO2S and catalyst monitor sensors. ^ Tighten to 40 Nm (30 ft. lbs.). 2. NOTE: RH side shown, LH similar. NOTE: Install new exhaust Y-pipe dual catalytic converter-to-exhaust manifold nuts. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Y-Pipe - Dual Catalytic Converter > Page 2433 Position the exhaust Y-pipe dual catalytic converter and loosely install the exhaust Y-pipe dual catalytic converter-to-exhaust manifold nuts. 3. NOTE: Install new exhaust Y-pipe dual catalytic converter-to-muffler assembly gasket, bolts and nuts. Loosely install the exhaust Y-pipe dual catalytic converter-to-muffler assembly gasket, bolts and nuts. 4. Install the transmission support crossmember. 5. Align the exhaust system. 6. Connect the HO2S and catalyst monitor sensors electrical connectors. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Y-Pipe - Dual Catalytic Converter > Page 2434 Exhaust Pipe: Service and Repair Tailpipe Tailpipe Removal WARNING: The normal operating temperature of the exhaust system is very high. Never work around or attempt to repair any part of the exhaust system until it has cooled. Use special care when working around the catalytic converter. The catalytic converter heats to a high temperature after only a short period of engine operation. Failure to follow these instructions may result in personal injury. CAUTION: Do not use oil or grease-based lubricants on the isolators. These lubricants may cause deterioration of the rubber. This can lead to separation of the isolator from the exhaust hanger bracket during vehicle operation. Use only water-based lubricants on the isolators. NOTE: Exhaust fasteners are of a prevailing torque design. Use only new fasteners with the same part number as the original. Torque values must be used as specified during reassembly to make sure of correct retention of exhaust components. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair 2. NOTE: When the muffler assembly-to-tailpipe Torca(R) clamp is loosened, a new muffler assembly-to-tailpipe Torca(R) clamp must be installed. Loosen the muffler assembly-to-tailpipe Torca(R) clamp. 3. Disconnect the rubber isolator and remove the tailpipe. Installation 1. If reusing the tailpipe, install a new muffler assembly-to-tailpipe Torca(R) clamp. 2. Position the tailpipe and connect the rubber isolator. 3. NOTE: Do not tighten the muffler assembly-to-tailpipe Torca(R) clamp until the exhaust system has been aligned. NOTE: Using an abrasive pad, clean the muffler assembly-to-tailpipe surface area of any rust. Position the muffler assembly-to-tailpipe. 4. Align the exhaust system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair Muffler: Service and Repair Muffler Removal All vehicles WARNING: The normal operating temperature of the exhaust system is very high. Never work around or attempt to repair any part of the exhaust system until it has cooled. Use special care when working around the catalytic converter. The catalytic converter heats to a high temperature after only a short period of engine operation. Failure to follow these instructions may result in personal injury. CAUTION: Do not use oil or grease-based lubricants on the isolators. These lubricants may cause deterioration of the rubber. This can lead to separation of the isolator from the exhaust hanger bracket during vehicle operation. Use only water-based lubricants on the isolators. NOTE: Exhaust fasteners are of a prevailing torque design. Use only new fasteners with the same part number as the original. Torque values must be used as specified during reassembly to make sure of correct retention of exhaust components. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair 2. Using a suitable jack, support the exhaust system. 4.0L Explorer Sport Trac 3. NOTE: The production muffler assembly is a one-piece design. The service muffler assembly is serviced with 2 pieces. NOTE: In order to remove the muffler assembly, you must cut the muffler inlet pipe. Using a suitable exhaust cutter, cut the muffler inlet pipe between the first bend coming out of the muffler and the next bend in line. If a service exhaust coupler is present at this point, loosen the service exhaust coupler nuts and separate the muffler inlet pipe. ^ Discard the service exhaust coupler. 4.6L Explorer Sport Trac 4. NOTE: The production muffler assembly is a one-piece design. The service muffler assembly is serviced with 2 pieces. NOTE: In order to remove the muffler assembly, you must cut the muffler inlet pipe. Using a suitable exhaust cutter, cut the muffler inlet pipe between the first bend coming out of the muffler and the next bend in line. If a service exhaust coupler is present at this point, loosen the service exhaust coupler nuts and separate the muffler inlet pipe. ^ Discard the service exhaust coupler. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 2438 All vehicles 5. NOTE: When the muffler assembly-to-tailpipe Torca(R) clamp is loosened, a new muffler assembly-to-tailpipe Torca(R) clamp must be installed. Loosen the muffler assembly-to-tailpipe Torca(R) clamp. 6. Remove the exhaust Y-pipe-dual catalytic converter-to-muffler assembly bolts, nuts and gasket. ^ Discard the exhaust Y-pipe-dual catalytic converter-to-muffler assembly bolts, nuts and gasket. 7. Disconnect the rubber isolators and remove the muffler assembly. Installation All vehicles 1. If reusing the tailpipe, install a new muffler assembly-to-tailpipe Torca(R) clamp. 2. Position the muffler assembly and connect the rubber isolators. 3. NOTE: Do not tighten the muffler assembly-to-tailpipe Torca(R) clamp until the exhaust system has been aligned. NOTE: Using an abrasive pad, clean the muffler assembly-to-tailpipe surface area of any rust. Position the muffler assembly-to-tailpipe. Explorer Sport Trac 4. NOTE: Install a new muffler inlet pipe service coupler. NOTE: Using an abrasive pad, clean the muffler inlet pipe service coupler surface area of any rust. NOTE: If installing a service muffler kit, the coupling will be welded into position on the muffler inlet pipe. NOTE: The factory muffler inlet pipe will not have an alignment nub. If reusing the factory muffler assembly, position the 2 halves of the muffler inlet pipe into the service exhaust coupler and center the service exhaust coupler onto the cut joint on the muffler inlet pipe. If installing a new service muffler kit, install the muffler inlet pipe coming out of the muffler into the service exhaust coupler. All Vehicles 5. NOTE: Install new exhaust Y-pipe-dual catalytic converter-to-muffler assembly gasket, bolts and nuts. Loosely install the exhaust Y-pipe-dual catalytic converter-to-muffler assembly gasket, bolts and nuts. 6. Align the exhaust system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Specifications Torque Specifications Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) Body Control Module: Service and Repair Driver Seat Module (DSM) DRIVER SEAT MODULE (DSM) Special Tool(s) Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 2447 Removal and Installation CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: Prior to the removal of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new DSM after installation. 1. Remove the driver seat. 2. Remove the 2 DSM screws. 3. Disconnect the electrical connectors and remove the DSM. 4. NOTE: Once the module is installed it is necessary to download the module configuration information from the scan tool into the new module. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 2448 Body Control Module: Service and Repair Smart Junction Box (Sjb) SMART JUNCTION BOX (SJB) Special Tool(s) Special Tool(s) Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 2449 Part 2 Removal NOTE: - The steps included in the SJB removal and installation procedure are critical to restoring the vehicle security and tire pressure monitoring systems to normal operation. A new SJB is delivered in manufacturing mode with 6 pre-set diagnostic trouble codes (DTCs) related to the tire pressure monitoring system. The presence of these DTCs requires the installation procedures be followed in order to clear the DTCs and enable normal SJB operations. - Prior to the removal of the SJB, it is necessary to upload the module configuration information to the diagnostic tool. This information must be downloaded to the new SJB after installation. 1. Remove the driver door scuff plate. 2. Position the LH door opening weather seal aside. 3. NOTE: While pulling the trim panel rearward, pull the hood release lever rearward in order for the release lever to slide through the trim panel. Remove the pushpin and the cowl side trim panel. 4. Remove the 2 bolts and the parking brake release handle. 5. Disconnect the parking brake switch electrical connector. 6. Release the hood release cable pushpin from the parking brake control bracket. 7. Release the harness clip from the parking brake cable housing. 8. NOTE: Rotating the parking brake control counterclockwise allows enough access to clear the instrument panel reinforcement. Remove the 3 bolts and position the parking brake control assembly under the brake pedal. 9. CAUTION: The lower side of the headlight switch bezel includes 2 tabs that slide down onto the instrument panel and may be broken if any prying force is exerted in the lower area of the bezel. Using a suitable tool, pry the mid-to-upper side of the headlight switch bezel away from the instrument panel, disconnect the 2 electrical connectors and position the bezel assembly aside. 10. If necessary, push the LH instrument panel side finish panel out and position it aside. 11. Through the headlight switch bezel opening, remove the 2 SJB bolts. 12. From under the instrument panel, remove the third SJB bolt. 13. NOTE: The SJB electrical connector levers must click into a fully released position before they can be removed and must click into a fully closed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 2450 (connected) position when installing. Pull the SJB down out of the 2 locating pins, disconnect the 5 electrical connectors and remove the SJB. Installation NOTE: When a new SJB is installed, all customer RKE transmitters may be required to program the RKE transmitters to the new SJB. 1. NOTE: The SJB electrical connector levers must click into a fully released position before they can be removed and must click into a fully closed (connected) position when installing. Position the SJB into the 2 locating pins and connect the 5 electrical connectors. 2. From under the instrument panel, install the SJB bolt. 3. Through the headlight switch bezel opening, install the 2 SJB bolts. 4. If necessary, install the LH instrument panel side finish panel. 5. Connect the 2 electrical connectors and install the headlight switch bezel assembly into the instrument panel. 6. Position the parking brake control assembly and install the 3 bolts. - Tighten to 20 Nm (15 lb-ft). 7. Install the harness clip on the parking brake cable housing. 8. Install the hood release cable pushpin into the parking brake control bracket. 9. Connect the parking brake switch electrical connector. 10. Position the parking brake release handle and install the 2 bolts. 11. Position the hood release lever assembly and install the bolt. 12. NOTE: While installing the trim panel, pull the hood release lever rearward in order for the release lever to slide through the trim panel. Position the cowl side trim panel and install the pushpin. 13. Position the LH door opening weather seal. 14. Install the driver door scuff plate. 15. NOTE: When successful, this step provides the calibration necessary for SJB operation and clears DTC B2477. The clearing of the DTC indicates the calibration data has been successfully downloaded to the SJB. Download the SJB configuration information from the diagnostic tool to the SJB. 16. NOTE: When successful, this step clears DTCs B2868, B2869, B2870 and B2871. The clearing of these DTCs indicates the SJB has recognized the tire pressure sensors during the training procedure. Train the tire pressure sensors. 17. Clear the DTCs. 18. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode, and to be sure there are no other concerns with the newly programmed SJB. Carry out the SJB on-demand self-test. 19. NOTE: If the module configuration upload/download is successful, then the RKE transmitters do not need to be reprogrammed to the vehicle. However, if the module configuration upload/download is unsuccessful and as-built data must be used to configure the module, then ALL of the customer's RKE transmitters must be reprogrammed to the vehicle. Program the RKE transmitters to the new SJB (if necessary). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation Electronic Throttle Control Module: Description and Operation TORQUE BASED ELECTRONIC THROTTLE CONTROL (ETC) Overview The torque based ETC is a hardware and software strategy that delivers an engine output torque (via throttle angle) based on driver demand (pedal position). It uses an electronic throttle body, the powertrain control module (PCM), and an accelerator pedal assembly to control the throttle opening and engine torque. The ETC system replaces the standard cable operated accelerator pedal, idle air control (IAC) valve, 3-wire throttle position (TP) sensor, and mechanical throttle body. Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque during shifts, and by calculating this desired torque, the system prevents engine lugging (low RPM and low manifold vacuum) while still delivering the performance and torque requested by the driver. It also enables many fuel economy/emission improvement technologies such as variable camshaft timing (VCT) (deliver same torque during transitions). Torque based ETC also results in less intrusive vehicle and engine speed limiting, along with smoother traction control. Other benefits of ETC are: eliminate cruise control actuators - eliminate idle air control (IAC) valve - better airflow range - packaging (no cable) - more responsive powertrain at altitude and improved shift quality It should be noted that the ETC system illuminates a powertrain malfunction indicator (wrench) on the instrument cluster when a concern is present. Concerns are accompanied by diagnostic trouble codes (DTCs) and may also illuminate the malfunction indicator lamp (MIL). Electronic Throttle Body (ETB) The ETB has the following characteristics: 1. The throttle actuator control (TAC) motor is a DC motor controlled by the PCM (requires 2-wires). The gear ratio from the motor to the throttle plate shaft is 17:1. 2. There are 2 designs: parallel and in-series. The parallel design has the motor under the bore parallel to the plate shaft. The motor housing is integrated into the main housing. The in-series design has a separate motor housing. 3. Two springs are used: one is used to close the throttle (main spring) and the other is in a plunger assembly that results in a default angle when no power is applied. This is for limp home reasons (the force of the plunger spring is 2 times stronger than the main spring). The default angle is usually set to result in a top vehicle speed of 48 km/h (30 mph). Typically this throttle angle is 7 to 8 degrees from the hard-stop angle. 4. The closed throttle plate hard stop is used to prevent the throttle from binding in the bore (~0.75 degree). This hard stop setting is not adjustable and is set to result in less airflow than the minimum engine airflow required at idle. 5. Unlike cable operated throttle bodies, the intent for the ETB is not to have a hole in the throttle plate or to use plate sealant. The hole is not required in the ETB because the required idle airflow is provided by the plate angle in the throttle body assembly. This plate angle controls idle, idle quality, and eliminates the need for an IAC valve. 6. The TP sensor has 2 signal circuits in the sensor for redundancy. The redundant throttle position signals are required for increased monitoring reasons. The first TP signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). During normal operation the negative slope TP signal (TP1) is used by the control strategy as the indication of throttle position. The TP sensor assembly requires 4 circuits. 5-volt reference voltage - Signal return (ground) - TP1 voltage with negative voltage slope (5-0 volts) - TP2 voltage with positive voltage slope (0-5 volts) Accelerator Pedal Position (APP) Sensors Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2454 Electronic Throttle Body (ETB) And Accelerator Pedal Assembly The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1. There are 3 pedal position signals required for system monitoring. APP1 has a negative slope (increasing angle, decreasing voltage) and APP2 and APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. 2. There are 2 VREF circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. 2 reference voltage circuits (5 volts) - 2 signal return (ground) circuits - APP1 voltage with negative voltage slope (5-0 volts) - APP2 voltage with positive voltage slope (0-5 volts) - APP3 voltage with positive voltage slope (0-5 volts) 3. The pedal position signal is convened to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. 4. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. A value is substituted for an incorrect signal if 2 of the 3 signals are incorrect. Electronic Throttle Control (ETC) System Strategy Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2455 ETC System The torque based ETC strategy was developed to improve fuel economy and to accommodate variable camshaft timing (VCT). This is possible by not coupling the throttle angle to the driver pedal position. Uncoupling the throttle angle (produce engine torque) from the pedal position (driver demand) allows the powertrain control strategy to optimize fuel control and transmission shift schedules while delivering the requested wheel torque. The ETC monitor system is distributed across 2 processors within the PCM: the main powertrain control processor unit (CPU) and a monitoring processor called an enhanced-quizzer (E-Quizzer) processor. The primary monitoring function is carried out by the independent plausibility check (IPC) software, which resides on the main processor. It is responsible for determining the driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the generated torque exceeds driver demand by a specified amount, the IPC takes appropriate corrective action. ETC System Failure Mode And Effects Management (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2456 ETC System Failure Mode And Effects Management (Part 2) Since the IPC and the main controller share the same processor, they are subject to a number of potential common failure modes. The E-Quizzer processor was added to redundantly monitor selected PCM inputs and to act as an intelligent watchdog and monitor the performance of the IPC and the main processor. If it determines that the IPC function is impaired in any way, it takes appropriate failure mode and effects management (FMEM) actions. Electronic Throttle Monitor Operation: Electronic Throttle Monitor Operation (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2457 Electronic Throttle Monitor Operation (Part 2) Accelerator and Throttle Position (TP) Sensor Inputs Accelerator Pedal Position (APP) Sensor Check: Accelerator Pedal Position (APP) Sensor Check Throttle Position (TP) Sensor Check: Throttle Position (TP) Sensor Check Throttle Plate Position Controller (TPPC) Outputs Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2458 Throttle Plate Controller Check Operation The purpose of the TPPC is to maintain the throttle position at the desired throttle angle. It is a separate chip embedded in the PCM. The desired angle is communicated from the main CPU via a 312.5 Hz duty cycle (DC) signal. The TPPC interprets the duty cycle signal as follows: Less than 4% - Out of range, limp home default position. - Greater than or equal to 4% but less than 6% - Commanded default position, closed. - Greater than or equal to 6% but less than 7% - Commanded default position. Used for key ON, engine OFF. - Greater than or equal to 7% but less than 8% - Enable ice breaker mode. Used to clear potential ice buildup in the throttle body. - Greater than or equal to 8% but less than 10% - Closed against hard-stop. Used to learn zero throttle angle position (hard stop) after key-up. - Greater than or equal to 10% but less than or equal to 92% - Normal operation, between 0 degrees (hard stop) and 82 degrees, 10% duty cycle equals 0 degrees throttle angle, 92% duty cycle equals 82 degrees throttle angle. - Greater than 92% but less than or equal to 96% - Wide open throttle, 82 to 86 degrees throttle angle. - Greater than 96% but less than or equal to 100% - Out of range, limp home default position. The desired angle is relative to the hard-stop angle. The hard stop angle is learned during each key-up process before the main CPU requests the throttle plate be closed against the hard stop. The output of the TPPC is a voltage request to the H driver (also in PCM). The H driver is capable of positive or negative voltage to the electronic throttle body motor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start Engine Control Module: Customer Interest Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start TSB 08-18-2 09/15/08 MIL ON - P0506 AND/OR P0505 - HESITATION/LOSS OF RPM/DIFFICULTY STARTING/LOW IDLE RPM FORD: 2005-2007 Crown Victoria 2006 Mustang, Mustang 2004-2006 F-150, F-150 2005-2006 E-350, E-450, F-Super Duty 2006 F-53 Motorhome Chassis 2006-2007 Explorer Sport Trac, Explorer LINCOLN: 2005-2007 Town Car 2006 Mark LT MERCURY: 2005-2007 Grand Marquis 2006-2007 Mountaineer, Mountaineer This article supersedes TSB(s) 08-5-13, 07-23-12 and 06-25-8 to update the Service Procedure. ISSUE Some 2004-2006 4.6L and 5.4L F-150 (excluding F-150 Heritage), 2006 5.4L Mark LT, 2005-2006 6.8L E-350 / E-450, 2005-2006 6.8L F-Super Duty (F-250 to F-550), 2006 6.8L F-53 Motorhome Chassis, 2006-2007 4.0L Explorer 4 dr, 2007 4.0L Explorer Sport Trac, 2006-2007 4.0L Mountaineer, 2006 4.0L Mustang, 2006 - 2007 4.6L 3V Explorer / Explorer Sport Trac / Mountaineer, 2006 4.6L 3V Mustang, and 2005-2007 Crown Vic / Grand Marquis / Towncar vehicles may exhibit one or more of the following symptoms: drive-away hesitation, loss of RPM on deceleration, difficulty starting, and/or idle RPM less than desired. Malfunction indicator lamp (MIL) may be illuminated with diagnostic trouble codes (DTCs) P0506 and/or P0505. These conditions may appear after battery disconnect, dead battery condition, or keep alive memory (KAM) reset. The symptoms may be due to engine deposits in the throttle leading to air[low less than desired. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 53.9 and higher or 54.1 and higher. This new calibration is not included in the VCM 2008.1 DVD. Calibration files may also be obtained at the website. The calibration contains a sludge compensation strategy for the throttle body. 2. Turn the key off to re-initialize the PCM. This will allow the sludge compensation strategy to learn. 3. With the vehicle in park or neutral and A/C off, start vehicle and allow engine to reach normal operating temperature(greater than 170 °F (77 °C) coolant temperature). Run an additional 5 minutes to allow sufficient learning time. 4. While the engine is running, using IDS datalogger or equivalent, check the PID value of ETC_TRIM. a. If ETC_TRIM value is 3.5 degrees, and/or DTC PuSE is present, then replace the electronic throttle body (ETB), following Workshop Manual (WSM), Section 303-04B. b. If ETC_TRIM value is less than 3.5 degrees and DTC PuSE is not present, but driveability concerns persist, the ETB is not the likely cause of the concern and replacement is not necessary. Continue with normal PC/ED diagnostics. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start > Page 2467 NOTE VEHICLES EQUIPPED WITH A PCM AND TCM REQUIRE COORDINATED REPROGRAMMING. THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS OUTLINED BY THE IDS. FAILURE TO FOLLOW THE KEY CYCLE PROCEDURE WITHOUT WAITING FOR THE IDS PROMPTS, WILL CAUSE THE COORDINATED REPROGRAMMING TO FAIL. THE PCM WILL BE UPDATED BUT THE 1CM WILL NOT BE UPDATED AND NEW FILES WILL NOT BE INSTALLED. IT IS CRITICAL TO FOLLOW THE IDS PROMPTS. SOME VEHICLES MAY REQUIRE SEVERAL DAYS OF DRIVING FOR THE TRANSMISSION TO FULLY ADAPT. REPROGRAMMING CONCERNS/ERRORS MAY BE CAUSED BY THE DATA LINK CONNECTOR (DLC) OR VEHICLE COMMUNICATION MODULE (VCM) BECOMING DISCONNECTED, LOW BATTERIES ON THE INTEGRATED DIAGNOSTIC SYSTEM (IDS) OR THE IDS GOING INTO ANY TYPE OF SLEEP MODE, OR LOW VEHICLE BATTERY VOLTAGE. IF THERE WAS AN INTERRUPTION DURING REPROGRAMMING, MAKE SURE THE ORIGINAL IDS SESSION THAT WAS CREATED FOR THE VEHICLE IS NOT DELETED. IF THE ORIGINAL VEHICLE SESSION IS NOT USED OR DELETED BEFORE THE MODULES ARE COMPLETELY REPROGRAMMED, FURTHER REPROGRAMMING ERRORS CAN OCCUR. THE MODULE RECOVERY PROCEDURE IS NO LONGER AVAILABLE AND IT IS CRITICAL THAT MODULE SWAPPING IS NOT PERFORMED FROM VEHICLE TO VEHICLE. TO REGAIN COMMUNICATION WITH A MODULE THAT HAS BEEN ERASED DURING REPROGRAMMING, RESUME THE ORIGINAL SESSION ONCE THE IDS IS RE-BOOTED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081802A 2004-2006 F-150 0.4 Hr. 4.6L/5.4L, 2006 Mark LT, Econoline 350/450 6.8L 2005-2006 F-Super Duty 6.8L, 2006-2007 Explorer/Mountaineer 4.0L, 2007 Explorer Sport Trac 4.0L, 2006 Mustang 4.OL, 2005-2007 Crown Victoria, Town Car, Grand Marquis: Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Authorization Decal NOT Necessary. (Do Not Use With 9926A, 12650D) 081802A 2006-2007 1.0 Hr. Explorer/Mountaineer 4.6L, 2007 Explorer Sport Trac 4.6L: Check For DICs And Reprogram The PCM And 1CM, Includes Time To Monitor ETC_Trim Value, Authorization Decal NOT Necessary. (Do Not Use With 9926A, 12650D) 081802B 2004-2006 F-150 5.4L, 0.9 Hr. 2006 Mark LT: Check For DTCs And Reprogram The PCM, Includes Time To Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start > Page 2468 Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2004-2006 F-150 4.6L: 0.8 Hr. Check For DTCs And Reprogram The PCM Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2005-2006 Econoline 6.8L: 1.1 Hrs. Check For DTCs And Reprogram The PCM Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2005-2006 F-Super Duty 0.9 Hr. 6.8L: Check For DTCs And Reprogram The PCM Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2006-2007 Explorer, 1.4 Hrs. Mountaineer 2007 Explorer Sport Trac 4.6L: Check For DTCs And Reprogram The PCM And TCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2006-2007 Explorer, 0.8 Hr. Mountaineer 2007 Explorer Sport Trac 4.0L: Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2005-2007 Crown Victoria, 0.8 Hr. Town Car, Grand Marquis: Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start > Page 2469 Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2006 Mustang 4.0L/4.6L: 0.8 Hr. Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start TSB 08-18-2 09/15/08 MIL ON - P0506 AND/OR P0505 - HESITATION/LOSS OF RPM/DIFFICULTY STARTING/LOW IDLE RPM FORD: 2005-2007 Crown Victoria 2006 Mustang, Mustang 2004-2006 F-150, F-150 2005-2006 E-350, E-450, F-Super Duty 2006 F-53 Motorhome Chassis 2006-2007 Explorer Sport Trac, Explorer LINCOLN: 2005-2007 Town Car 2006 Mark LT MERCURY: 2005-2007 Grand Marquis 2006-2007 Mountaineer, Mountaineer This article supersedes TSB(s) 08-5-13, 07-23-12 and 06-25-8 to update the Service Procedure. ISSUE Some 2004-2006 4.6L and 5.4L F-150 (excluding F-150 Heritage), 2006 5.4L Mark LT, 2005-2006 6.8L E-350 / E-450, 2005-2006 6.8L F-Super Duty (F-250 to F-550), 2006 6.8L F-53 Motorhome Chassis, 2006-2007 4.0L Explorer 4 dr, 2007 4.0L Explorer Sport Trac, 2006-2007 4.0L Mountaineer, 2006 4.0L Mustang, 2006 - 2007 4.6L 3V Explorer / Explorer Sport Trac / Mountaineer, 2006 4.6L 3V Mustang, and 2005-2007 Crown Vic / Grand Marquis / Towncar vehicles may exhibit one or more of the following symptoms: drive-away hesitation, loss of RPM on deceleration, difficulty starting, and/or idle RPM less than desired. Malfunction indicator lamp (MIL) may be illuminated with diagnostic trouble codes (DTCs) P0506 and/or P0505. These conditions may appear after battery disconnect, dead battery condition, or keep alive memory (KAM) reset. The symptoms may be due to engine deposits in the throttle leading to air[low less than desired. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 53.9 and higher or 54.1 and higher. This new calibration is not included in the VCM 2008.1 DVD. Calibration files may also be obtained at the website. The calibration contains a sludge compensation strategy for the throttle body. 2. Turn the key off to re-initialize the PCM. This will allow the sludge compensation strategy to learn. 3. With the vehicle in park or neutral and A/C off, start vehicle and allow engine to reach normal operating temperature(greater than 170 °F (77 °C) coolant temperature). Run an additional 5 minutes to allow sufficient learning time. 4. While the engine is running, using IDS datalogger or equivalent, check the PID value of ETC_TRIM. a. If ETC_TRIM value is 3.5 degrees, and/or DTC PuSE is present, then replace the electronic throttle body (ETB), following Workshop Manual (WSM), Section 303-04B. b. If ETC_TRIM value is less than 3.5 degrees and DTC PuSE is not present, but driveability concerns persist, the ETB is not the likely cause of the concern and replacement is not necessary. Continue with normal PC/ED diagnostics. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start > Page 2475 NOTE VEHICLES EQUIPPED WITH A PCM AND TCM REQUIRE COORDINATED REPROGRAMMING. THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS OUTLINED BY THE IDS. FAILURE TO FOLLOW THE KEY CYCLE PROCEDURE WITHOUT WAITING FOR THE IDS PROMPTS, WILL CAUSE THE COORDINATED REPROGRAMMING TO FAIL. THE PCM WILL BE UPDATED BUT THE 1CM WILL NOT BE UPDATED AND NEW FILES WILL NOT BE INSTALLED. IT IS CRITICAL TO FOLLOW THE IDS PROMPTS. SOME VEHICLES MAY REQUIRE SEVERAL DAYS OF DRIVING FOR THE TRANSMISSION TO FULLY ADAPT. REPROGRAMMING CONCERNS/ERRORS MAY BE CAUSED BY THE DATA LINK CONNECTOR (DLC) OR VEHICLE COMMUNICATION MODULE (VCM) BECOMING DISCONNECTED, LOW BATTERIES ON THE INTEGRATED DIAGNOSTIC SYSTEM (IDS) OR THE IDS GOING INTO ANY TYPE OF SLEEP MODE, OR LOW VEHICLE BATTERY VOLTAGE. IF THERE WAS AN INTERRUPTION DURING REPROGRAMMING, MAKE SURE THE ORIGINAL IDS SESSION THAT WAS CREATED FOR THE VEHICLE IS NOT DELETED. IF THE ORIGINAL VEHICLE SESSION IS NOT USED OR DELETED BEFORE THE MODULES ARE COMPLETELY REPROGRAMMED, FURTHER REPROGRAMMING ERRORS CAN OCCUR. THE MODULE RECOVERY PROCEDURE IS NO LONGER AVAILABLE AND IT IS CRITICAL THAT MODULE SWAPPING IS NOT PERFORMED FROM VEHICLE TO VEHICLE. TO REGAIN COMMUNICATION WITH A MODULE THAT HAS BEEN ERASED DURING REPROGRAMMING, RESUME THE ORIGINAL SESSION ONCE THE IDS IS RE-BOOTED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081802A 2004-2006 F-150 0.4 Hr. 4.6L/5.4L, 2006 Mark LT, Econoline 350/450 6.8L 2005-2006 F-Super Duty 6.8L, 2006-2007 Explorer/Mountaineer 4.0L, 2007 Explorer Sport Trac 4.0L, 2006 Mustang 4.OL, 2005-2007 Crown Victoria, Town Car, Grand Marquis: Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Authorization Decal NOT Necessary. (Do Not Use With 9926A, 12650D) 081802A 2006-2007 1.0 Hr. Explorer/Mountaineer 4.6L, 2007 Explorer Sport Trac 4.6L: Check For DICs And Reprogram The PCM And 1CM, Includes Time To Monitor ETC_Trim Value, Authorization Decal NOT Necessary. (Do Not Use With 9926A, 12650D) 081802B 2004-2006 F-150 5.4L, 0.9 Hr. 2006 Mark LT: Check For DTCs And Reprogram The PCM, Includes Time To Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start > Page 2476 Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2004-2006 F-150 4.6L: 0.8 Hr. Check For DTCs And Reprogram The PCM Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2005-2006 Econoline 6.8L: 1.1 Hrs. Check For DTCs And Reprogram The PCM Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2005-2006 F-Super Duty 0.9 Hr. 6.8L: Check For DTCs And Reprogram The PCM Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2006-2007 Explorer, 1.4 Hrs. Mountaineer 2007 Explorer Sport Trac 4.6L: Check For DTCs And Reprogram The PCM And TCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2006-2007 Explorer, 0.8 Hr. Mountaineer 2007 Explorer Sport Trac 4.0L: Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2005-2007 Crown Victoria, 0.8 Hr. Town Car, Grand Marquis: Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start > Page 2477 Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2006 Mustang 4.0L/4.6L: 0.8 Hr. Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2478 Engine Control Module: Locations View 151-1 (Engine Compartment - 4.0L, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2479 View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2482 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2483 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2484 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2485 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2486 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2487 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2488 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2489 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2490 Engine Control Module: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2491 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2492 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2493 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2494 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2495 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2496 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2497 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2498 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2499 Engine Control Module: Connector Views C175B (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2500 C175B (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2501 C175E (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2502 C175E (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2503 C175T (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2504 C175T (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) Engine Control Module: Service and Repair Powertrain Control Module (PCM) POWERTRAIN CONTROL MODULE (PCM) Removal All vehicles 1. NOTE: Powertrain control module (PCM) installation DOES NOT require new keys. Retrieve the module configuration. Carry out the module configuration retrieval steps of the Programmable Module Installation procedure. Vehicles equipped with a 4.6L (3V) engine 2. Remove the air cleaner. All vehicles Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) > Page 2507 3. Disconnect the RH front wheel speed sensor electrical connector. Remove the nuts and position the A/C tube brackets and wiring harness aside. 4. Disconnect the PCM connectors. 5. Remove the bolts and the PCM. Installation All vehicles 1. Install the PCM and bolts. - Tighten to 10 Nm (89 lb-in). 2. Connect the PCM electrical connectors. 3. Position the wiring harness and the A/C tube brackets and install the nuts. Connect the RH front wheel speed sensor electrical connector. - Tighten to 7 Nm (62 lb-in). Vehicles equipped with a 4.6L (3V) engine 4. Install the air cleaner. All vehicles 5. Restore the module configuration. Carry out the module configuration restore steps of the Programmable Module Installation procedure. 6. Reprogram the passive anti-theft system (PATS). Carry out the Parameter Reset procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) > Page 2508 Engine Control Module: Service and Repair Flash Electrically Erasable Programmable Read Only Memory (EEPROM) FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) Description The 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 programmed or flashed repeatedly. As part of the calibration there is an area referred to as the vehicle identification (VID) block. The VID block is programmed when installing a new PCM as described under Programming the VID Block for a Replacement PCM. Failure to carry out this procedure may generate DTCs P1635 or P1639. The VID block in an existing PCM can also be tailored to accommodate various hardware or parameter changes made to the vehicle since production. Failure to carry out this procedure properly may generate DTC P1635, Tire/Axle Ratio out of Acceptable Range. An incorrect tire/axle ratio is one of the main causes for DTC P1639. 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 vehicle identification number (VIN), octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control, and 4-wheel drive electronic shift-on-the-fly (ESOF) versus manual shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported by the VID block is displayed on the scan tool. When changing items in the VID block, the strategy places range limits on certain items such as tire and axle ratio. The number of times the VID block may be reconfigured is limited. When this limit is reached, the scan tool displays a message indicating the need to flash the PCM again to reset the VID block. Programming can be carried out by a local Ford dealer or any non-Ford facility. Refer to the scan tool manufacturer's instruction manual for details. Programming the VID Block for a Replacement PCM A new PCM contains the latest strategy and calibration level for a particular vehicle. However, the VID block is blank and needs programming. There are 2 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 is carried out if the old PCM is capable of communicating. This is done by using a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can then be downloaded to the new PCM after it has been installed. Carry out manual data entry if the old module is damaged or incapable of communicating. Remove and install a new PCM. Using a compatible scan tool, select and carry out the module/parameter programming, referring to the scan tool manufacturer's instruction manual. Make certain that all parameters are included. Failure to properly program tire size in revolutions per mile, (rev/mile equals 63,360 divided by the tire circumference in inches), axle ratio, 4x4/4x2, and/or MSOF/ESOF may result in DTCs P1635 and P1639. 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 and Lincoln Mercury technicians, contact your National Hotline or the Professional Technician Society (PTS) website for As-Built data listed under the Service Publications Index. Non-Ford technicians use the Motorcraft(R) website at www.motorcraft.com. From the Motorcraft(R) homepage, use the search function to find the Module Programming or As-Built Data. For Ford and Lincoln Mercury technicians, check the Programmable Module Installation link on the PTS website for quick Programmable Module data information by vehicle. Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate the vehicle hardware. Refer to Module Reprogramming on the scan tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM needs 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 Module Reprogramming on the scan tool. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2512 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Emission Control Systems > EGR Control Module > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Emission Control Systems > EGR Control Module > Component Information > Locations > Page 2517 C1450 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations View 151-17 (Right Rear, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 2522 C4033 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 2523 Fuel Pump Control Unit: Service and Repair FUEL PUMP DRIVER MODULE (FPDM) Removal and Installation 1. Remove the RH rear quarter trim panel. 2. Disconnect the fuel pump driver module (FPDM) electrical connector. 3. Remove the bolts and the FPDM. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 2527 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2531 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 2536 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations View 151-11 (behind Dash Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2542 C2040 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2543 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The APP sensor is an input to the powertrain control module (PCM) and is used to determine the torque demand. There are 3 pedal position signals in the sensor. Signal 1, APPS1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, APPS2 and APPS3, both have a positive slope (increasing angle, increasing voltage). During normal operation APPS1 is used as the indication of pedal position by the strategy. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. There are 2 reference voltage circuits and 2 signal return circuits for the sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2547 C128 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2548 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW (MAF) SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT Sensor Wire Where Applicable) Terminals Typical Mass Air Flow (MAF) Sensor Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2549 Typical Drop-in Mass Air Flow (MAF) Sensor The 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 the ambient temperature as measured by a constant cold wire. The current required to maintain the temperature of the hot wire is proportional to the mass air 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. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Most MAF sensors have integrated bypass technology with an integrated intake air temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2550 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Disconnect the mass air flow (MAF) sensor electrical connector. 2. Remove the bolts and the MAF. - To install, tighten to 2 Nm (18 lb-in). 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor C180 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 2556 C1366 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 2557 C1367 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2558 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR Typical Synchronizer Hall-Effect CMP Sensor Typical Variable Reluctance CMP Sensor The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to select the correct ignition coil to fire. Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor and the 2-pin connector variable reluctance type sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2559 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation 1. Disconnect the camshaft position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. - To install, tighten to 6 Nm (53 lb-in). 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Description and Operation Clutch Switch: Description and Operation CLUTCH PEDAL POSITION (CPP) SWITCH Typical Clutch Pedal Position (CPP) Switch The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine load. The PCM uses the load information for mass air flow and fuel calculations. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Locations > Page 2566 C1064 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Locations > Page 2567 Coolant Temperature Sensor/Switch (For Computer): Description and Operation ENGINE COOLANT TEMPERATURE (ECT) SENSOR Typical Thread Type ECT Sensor The ECT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance changes 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 PCM uses the ECT input for fuel control and for cooling fan control. There are 3 types of ECT sensors, threaded, push-in, and twist-lock. The ECT sensor is located in an engine coolant passage. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Locations > Page 2568 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR Removal and Installation 1. Drain the cooling system. 2. Disconnect the engine coolant temperature (ECT) sensor electrical connector. 3. Remove the clip and the ECT sensor. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2572 Crankshaft Position Sensor: Diagrams C101 C1120 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2573 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Typical Crankshaft Position (CKP) Sensor The 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 PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L 10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor 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 a fixed reference for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid deceleration between teeth. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2574 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). 4. NOTE: Be sure the sensor wiring is routed away from the battery cable. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Diagrams C107 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Diagrams > Page 2578 Engine Temperature Sensor: Description and Operation CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical CHT Sensor The CHT sensor is a thermistor device in which resistance changes with the temperature. The electrical resistance of a thermistor decreases as temperature increases., and the resistance 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. The CHT sensor is installed in the 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 initiates a fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern 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. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations View 151-14 (Right Front) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2582 Fuel Level Sensor: Diagrams C434A C434B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2583 Fuel Level Sensor: Description and Operation FUEL LEVEL INPUT (FLI) The FLI is a communications network message. Most vehicle applications use a potentiometer type FLI sensor connected to a float in the FP module to determine fuel level. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2584 Fuel Level Sensor: Service and Repair FUEL LEVEL SENSOR Explorer Sport Trac (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2585 Explorer Sport Trac (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2586 Explorer/Mountaineer (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2587 Explorer/Mountaineer (Part 2) All Vehicles (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2588 All Vehicles (Part 2) Removal 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. 1. Remove the fuel pump. 2. NOTE: Note the routing of the sending unit wire for installation. Remove the heat shrink tube covering the electrical connector. 3. Disconnect the electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2589 4. Remove the screw and lift up to remove the fuel gauge sending unit. Installation 1. Route the fuel gauge sending unit wire through the center of the fuel pump module. 2. NOTE: - Both fuel gauge sending wires must be routed behind the metal sending unit plate. - The grounding eyelet must be on the front side of the sending unit. Hook the fuel gauge sending unit on the fuel pump module and install the screw through the grounding eyelet and tighten the screw. 3. Slide the heat shrink tube onto the wire harness and connect the electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2590 4. WARNING: Do not use an open flame to shrink the heat shrink tube, use a heat gun only. Failure to follow these instructions may result in personal injury. Using a heat gun, shrink the heat shrink tube. 5. Install the fuel pump. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE (FTP) SENSOR Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The FTP sensor or in-line FTP sensor is used to measure the fuel tank pressure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Page 2594 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR Removal and Installation WARNING: - The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not present in large quantities, it still presents a danger or 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 cause 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. 1. Remove the evaporative emission (EVAP) canister. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Page 2595 2. Remove the fuel tank shield from the fuel tank. 3. Disconnect the fuel tank pressure sensor electrical connector. 4. Disconnect the 3 fuel tank pressure sensor and tube assembly quick connect couplings from the fuel pump module and the vapor vent valves. 5. Remove the fuel tank pressure sensor and tube assembly. 6. To install, reverse the removal procedure. 7. Leak test the evaporative emission system. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Evaporative Emission System Leak Test 8. Carry out the evaporative emission repair verification drive cycle. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Evaporative Emission Repair Verification Drive Cycle Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2599 C128 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2600 Intake Air Temperature Sensor: Description and Operation INTAKE AIR TEMPERATURE (IAT) SENSOR Typical Stand-Alone/Non-Integrated Intake Air Temperature (IAT) Sensors Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into A Drop-in Or Flange-type MAF Sensor The IAT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance 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 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 air flow. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2601 The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Currently there are 2 design types of IAT sensors used, a stand-alone/non-integrated type and a integrated type. Both types function the same, however the integrated type is incorporated into the mass air flow (MAF) sensor instead of being a stand alone sensor. Supercharged vehicles use 2 IAT sensors. Both sensors are thermistor type devices and operate as described. One is located before the supercharger at the air cleaner for standard OBD/cold weather input, while a second sensor (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 spark and to help determine charge air cooler (CAC) efficiency. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2605 C108 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2606 Knock Sensor: Description and Operation KNOCK SENSOR (KS) Two Types Of Knock Sensor (KS) The KS 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2607 Knock Sensor: Service and Repair KNOCK SENSOR (KS) Removal and Installation 1. Remove the intake manifold. 2. Disconnect the knock sensor (KS) electrical connector. 3. Remove the bolt and the KS. - To install, tighten to 20 Nm (15 lb-ft). 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation Manifold Pressure/Vacuum Sensor: Description and Operation MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR Typical Manifold Absolute Pressure (MAP) Sensor The MAP sensor measures intake manifold absolute pressure. The PCM uses information from the MAP sensor to measure how much exhaust gas is introduced into the intake manifold. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Diagrams C104 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Diagrams > Page 2614 Oil Temperature Sensor For ECM: Description and Operation ENGINE OIL TEMPERATURE (EOT) SENSOR Typical EOT Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance changes 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 EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system. The PCM can use the EOT sensor input to determine the following: - On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM begins reducing power by disabling engine cylinders. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Diagrams > Page 2615 Oil Temperature Sensor For ECM: Service and Repair OIL TEMPERATURE SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine oil. - Install the drain plug and tighten to 26 Nm (19 lb-ft). 3. Disconnect the oil temperature sensor electrical connector. 4. Remove the oil temperature sensor. - To install, tighten to 15 Nm (11 lb-ft). 5. To install, reverse the removal procedure. - Inspect the O-ring seal and install a new O-ring seal if necessary. - Fill the engine with clean engine oil. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2620 View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2621 View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2622 View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 C141 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 2625 C142 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 2626 C171 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 2627 C172 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2628 Oxygen Sensor: Description and Operation HEATED OXYGEN SENSOR (HO2S) Heated Oxygen Sensor (HO2S) The HO2S 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 voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a 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 a temperature of 800°C (1,472°F). At approximately 300°C (572°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater. The PCM turns the heater on by providing the ground when the correct conditions occur. The heater allows the engine to enter closed loop operation sooner. The use of this heater requires the HO2S heater control to be duty cycled, to prevent damage to the heater. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) HEATED OXYGEN SENSOR (HO2S) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 2631 Exploded View Special Tool(s) Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If the RH heated oxygen sensor (HO2S) is being serviced, remove the bolts and position the heat shield aside. - To install, tighten to 20 Nm (15 lb-ft). 3. Disconnect the HO2S electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 2632 4. NOTE: If necessary, lubricate the HO2S with penetrating and lock lubricant to ease removal. Using the special tool, remove the HO2S. To install, tighten to 41 Nm (30 lb-ft). 5. To install, reverse the removal procedure. - Apply a light coat of nickel anti-seize lubricant to the threads of the HO2S. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 2633 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor CATALYST MONITOR SENSOR Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 2634 Exploded View Special Tool(s) Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the catalyst monitor sensor electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 2635 3. NOTE: If necessary, lubricate the catalyst monitor sensor with penetrating and lock lubricant to ease removal. Using the special tool, remove the catalyst monitor sensor. To install, tighten to 41 Nm (30 lb-ft). 4. To install, reverse the removal procedure. - Apply a light coat of anti-seize lubricant to the threads of the catalyst monitor sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations View 151-2 (Engine Compartment - 4.0L, (2 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2639 C121 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch POWER STEERING PRESSURE (PSP) SWITCH Typical Power Steering Pressure (PSP) Switch The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch > Page 2642 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor POWER STEERING PRESSURE (PSP) SENSOR Typical Power Steering Pressure (PSP) Sensor The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM changes as the hydraulic pressure changes. The PCM uses the input signal from the PSP sensor to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP sensor signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example, during parking maneuvers. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor The differential pressure feedback EGR sensor 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 EGR sensor receives this signal through 2 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 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. DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR TUBE MOUNTED Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 2646 The tube mounted differential pressure feedback EGR sensor is identical in operation as the large plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 2647 Pressure Feedback Exhaust Sensor: Service and Repair EXHAUST GAS RECIRCULATION (EGR) SYSTEM MODULE Exploded View Removal and Installation 1. Disconnect the exhaust gas recirculation (EGR) system module electrical and vacuum connectors. 2. Disconnect the EGR system module-to-exhaust manifold tube upper fitting. - To install, tighten to 40 Nm (30 lb-ft). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 2648 3. NOTE: When installing the new EGR module gasket, install with the side with the raised circle facing the intake manifold. Remove the bolts, the EGR system module and the gasket. Discard the gasket. To install, tighten to 25 Nm (18 lb-ft). 4. NOTE: The EGR system module sealing surfaces are soft metals. Carefully clean the EGR system module sealing surfaces. 5. To install, reverse the removal procedure. - Install a new EGR system module gasket. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2652 C189 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Electronic Throttle Body (ETB) Position Sensor Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR The ETB position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB position signals are required for increased monitoring. The first ETB position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). During normal operation the negative slope ETB position sensor signal (TP1) is used by the control strategy as the indication of throttle position. The 2 ETB position sensor signals make sure the PCM receives a correct input even if 1 signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Electronic Throttle Body (ETB) Position Sensor > Page 2655 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor THROTTLE POSITION (TP) SENSOR Typical TP Sensor The TP sensor 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 3-blade electrical connector that may be gold plated. The gold plating increases the corrosion resistance on the terminals and increases the connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM from the TP. The operating 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) - throttle angle rate Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 2656 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Removal Vehicles equipped with a 4.6L (3V) engine 1. Remove the air cleaner outlet pipe. 2. Remove the bolts and position the heated positive crankcase ventilation (PCV) fitting and hoses aside. - Remove and discard the O-ring seal. All vehicles 3. Disconnect the throttle position (TP) sensor electrical connector. 4. CAUTION: Failure to remove the TP sensor screws in the following manner will result in damage to the screws. First loosen the screws 1-2 full turns using a hand tool and then use a suitable high-speed driver to complete the removal. Remove and discard the 2 screws and the TP sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 2657 Installation All vehicles 1. CAUTION: - Do not reuse the TP sensor and screws. A new TP sensor and screws must be installed. - Do not use a high-speed driver to install the new screws or damage to the TP sensor can occur. NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor is aligned with the radial locator hole on the throttle body. Position the new TP sensor and install the 2 new screws. Tighten to 3 Nm (27 lb-in). 2. Connect the TP sensor electrical connector. Vehicles equipped with a 4.6L (3V) engine 3. Install a new O-ring seal, position the heated PCV fitting and install the bolts. 4. Install the air cleaner outlet pipe. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2663 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2664 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2665 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2666 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2667 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2668 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2669 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2670 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2671 Transmission Position Switch/Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2672 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2673 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2674 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2675 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2676 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2677 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2678 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2679 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2680 C167 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2681 Transmission Position Switch/Sensor: Testing and Inspection Digital Transmission Range (TR) Sensor Diagnosis Chart Digital Transmission Range (TR) Sensor Diagnosis Chart Wiggle Test Information for Open/Shorts ^ TR4, TR3A, TR2 and TR1 are all closed in PARK. PARK is a good position to check for intermittent open circuits (with scan tool monitoring TRD). ^ TR4, TR3A, TR2 and TR1 are all open in OVERDRIVE, so OVERDRIVE is a good position to check for shorts to ground. To determine the shorted components while observing TRD, unplug the TR and determine if the short goes away. If the short is still present unplug the transmission harness and determine if the short goes away. If the short is still present, then the short is in the PCM or vehicle harness. Remove the suspect circuit(s) wire terminal from the PCM connector. If the short is still present, then the PCM has an internal failure, otherwise the failure is in the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2682 Transmission Position Switch/Sensor: Adjustments Transmission Range (TR) Sensor Adjustment Special Tool(s) Adjust 1. With the vehicle in NEUTRAL, position it on a hoist For additional information, refer to Maintenance/Service and Repair. 2. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the connector. 4. Disconnect the digital transmission range (TR) sensor electrical connector. 5. Remove the range selector lever cable end from the manual control lever. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2683 6. Remove the outer manual control lever. 7. Loosen but do not remove the digital TR sensor screws. 8. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. ^ Tighten to 8 Nm (71 inch lbs.) 9. Install the outer manual lever. ^ Tighten to 48 Nm (35 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2684 10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable end onto the manual control lever. 11. Reconnect the digital TR sensor electrical connector. 12. Move the rubber boot back over the connector. 13. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2685 14. Verify that the selector lever cable is adjusted correctly. 15. Verify that the vehicle will start in PARK and NEUTRAL and that the reverse lamps illuminate in REVERSE. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2686 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the connector. 4. Disconnect the digital transmission range (TR) sensor electrical connector. 5. Remove the selector lever cable from the manual control lever. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2687 6. Remove the outer manual control lever. 7. Remove the digital TR sensor. Installation 1. CAUTION: The digital transmission range sensor must fit flush against the boss on the case to prevent damage to the sensor. Install the digital TR sensor and 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 be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2688 ^ Tighten to 8 Nm (71 inch lbs.) 3. Install the outer manual lever. ^ Tighten to 48 Nm (35 ft. lbs.) 4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable to the manual control lever. 5. Connect the digital TR sensor electrical connector. 6. Move the rubber boot back over the connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2689 7. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. 8. Verify that the selector lever cable is adjusted correctly. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Output Shaft Speed (OSS) Sensor Vehicle Speed Sensor: Description and Operation Output Shaft Speed (OSS) Sensor OUTPUT SHAFT SPEED (OSS) SENSOR The OSS sensor provides the 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 that is generated. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Output Shaft Speed (OSS) Sensor > Page 2694 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) VEHICLE SPEED SENSOR (VSS) Typical Vehicle Speed Sensor (VSS) The VSS 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor The differential pressure feedback EGR sensor 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 EGR sensor receives this signal through 2 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 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. DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR TUBE MOUNTED Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 2699 The tube mounted differential pressure feedback EGR sensor is identical in operation as the large plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 2700 Pressure Feedback Exhaust Sensor: Service and Repair EXHAUST GAS RECIRCULATION (EGR) SYSTEM MODULE Exploded View Removal and Installation 1. Disconnect the exhaust gas recirculation (EGR) system module electrical and vacuum connectors. 2. Disconnect the EGR system module-to-exhaust manifold tube upper fitting. - To install, tighten to 40 Nm (30 lb-ft). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 2701 3. NOTE: When installing the new EGR module gasket, install with the side with the raised circle facing the intake manifold. Remove the bolts, the EGR system module and the gasket. Discard the gasket. To install, tighten to 25 Nm (18 lb-ft). 4. NOTE: The EGR system module sealing surfaces are soft metals. Carefully clean the EGR system module sealing surfaces. 5. To install, reverse the removal procedure. - Install a new EGR system module gasket. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations View 151-11 (behind Dash Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2706 C2040 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2707 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The APP sensor is an input to the powertrain control module (PCM) and is used to determine the torque demand. There are 3 pedal position signals in the sensor. Signal 1, APPS1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, APPS2 and APPS3, both have a positive slope (increasing angle, increasing voltage). During normal operation APPS1 is used as the indication of pedal position by the strategy. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. There are 2 reference voltage circuits and 2 signal return circuits for the sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2711 C128 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2712 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW (MAF) SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT Sensor Wire Where Applicable) Terminals Typical Mass Air Flow (MAF) Sensor Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2713 Typical Drop-in Mass Air Flow (MAF) Sensor The 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 the ambient temperature as measured by a constant cold wire. The current required to maintain the temperature of the hot wire is proportional to the mass air 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. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Most MAF sensors have integrated bypass technology with an integrated intake air temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2714 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Disconnect the mass air flow (MAF) sensor electrical connector. 2. Remove the bolts and the MAF. - To install, tighten to 2 Nm (18 lb-in). 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Fuel Tank Pressure Transducer Sensor View 151-14 (Right Front) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Fuel Tank Pressure Transducer Sensor > Page 2719 View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Fuel Rail Pressure/Temperature Sensor C173 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Fuel Rail Pressure/Temperature Sensor > Page 2722 C435 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Rail Pressure (FRP) Sensor Fuel Pressure Sensor/Switch: Description and Operation Fuel Rail Pressure (FRP) Sensor FUEL RAIL PRESSURE (FRP) SENSOR Fuel Rail Pressure (FRP) Sensor The FRP sensor is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and the resistance decreases as the 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. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Rail Pressure (FRP) Sensor > Page 2725 Fuel Pressure Sensor/Switch: Description and Operation Fuel Rail Pressure Temperature (FRPT) Sensor FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR Typical Fuel Rail Pressure Temperature (FRPT) Sensor The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to determine the pressure difference between the fuel rail and the intake manifold. The relationship between fuel pressure and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. The temperature sensing portion of the FRPT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of the thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Both the pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves 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 (V6-4.0L VIN K (2007)) 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 > Page 2726 Fuel Pressure Sensor/Switch: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE SENSOR Removal and Installation 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. Release the fuel system pressure. 2. Remove the intake manifold. 3. Disconnect the fuel rail pressure and temperature sensor vacuum and electrical connectors. 4. Remove the bolts and the fuel rail pressure and temperature sensor. - To install, tighten to 6 Nm (53 lb-in). 5. Remove and discard the O-ring seal. 6. CAUTION: Use an O-ring seal made of special fuel resistant material. Use of an ordinary O-ring seal can cause the fuel system to leak. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Page 2727 Do not reuse the O-ring seal. To install, reverse the removal procedure. Lubricate the new O-ring seal with clean engine oil. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 2731 C173 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 2732 Fuel Temperature Sensor: Description and Operation FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR Typical Fuel Rail Pressure Temperature (FRPT) Sensor The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to determine the pressure difference between the fuel rail and the intake manifold. The relationship between fuel pressure and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. The temperature sensing portion of the FRPT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of the thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Both the pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 2733 Fuel Temperature Sensor: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE SENSOR Removal and Installation 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. Release the fuel system pressure. 2. Remove the intake manifold. 3. Disconnect the fuel rail pressure and temperature sensor vacuum and electrical connectors. 4. Remove the bolts and the fuel rail pressure and temperature sensor. - To install, tighten to 6 Nm (53 lb-in). 5. Remove and discard the O-ring seal. 6. CAUTION: Use an O-ring seal made of special fuel resistant material. Use of an ordinary O-ring seal can cause the fuel system to leak. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 2734 Do not reuse the O-ring seal. To install, reverse the removal procedure. Lubricate the new O-ring seal with clean engine oil. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 View 151-11 (behind Dash Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 2738 C282 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 2739 Inertia Fuel Shutoff Switch: Description and Operation INERTIA FUEL SHUTOFF (IFS) SWITCH Typical Inertia Fuel Shutoff (IFS) Switch The IFS switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shutoff 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's Literature for the location of the IFS. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 2740 Inertia Fuel Shutoff Switch: Service and Repair INERTIA FUEL SHUTOFF (IFS) SWITCH Removal and Installation 1. NOTE: The front passenger door frame scuff plate is retained only by internal metal clips. Remove the front passenger door frame scuff plate. 2. NOTE: - The front passenger door side interior kick panel is retained only by internal metal clips. - It may be necessary to reposition the lower end of the door jam weather stripping to remove the front passenger door side interior kick panel. Remove the front passenger side interior kick panel. 3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Remove the bolts and the IFS switch - To install, tighten to 2 Nm (18 lb-in). 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 2744 C189 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Electronic Throttle Body (ETB) Position Sensor Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR The ETB position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB position signals are required for increased monitoring. The first ETB position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). During normal operation the negative slope ETB position sensor signal (TP1) is used by the control strategy as the indication of throttle position. The 2 ETB position sensor signals make sure the PCM receives a correct input even if 1 signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Electronic Throttle Body (ETB) Position Sensor > Page 2747 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor THROTTLE POSITION (TP) SENSOR Typical TP Sensor The TP sensor 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 3-blade electrical connector that may be gold plated. The gold plating increases the corrosion resistance on the terminals and increases the connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM from the TP. The operating 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) - throttle angle rate Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 2748 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Removal Vehicles equipped with a 4.6L (3V) engine 1. Remove the air cleaner outlet pipe. 2. Remove the bolts and position the heated positive crankcase ventilation (PCV) fitting and hoses aside. - Remove and discard the O-ring seal. All vehicles 3. Disconnect the throttle position (TP) sensor electrical connector. 4. CAUTION: Failure to remove the TP sensor screws in the following manner will result in damage to the screws. First loosen the screws 1-2 full turns using a hand tool and then use a suitable high-speed driver to complete the removal. Remove and discard the 2 screws and the TP sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 2749 Installation All vehicles 1. CAUTION: - Do not reuse the TP sensor and screws. A new TP sensor and screws must be installed. - Do not use a high-speed driver to install the new screws or damage to the TP sensor can occur. NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor is aligned with the radial locator hole on the throttle body. Position the new TP sensor and install the 2 new screws. Tighten to 3 Nm (27 lb-in). 2. Connect the TP sensor electrical connector. Vehicles equipped with a 4.6L (3V) engine 3. Install a new O-ring seal, position the heated PCV fitting and install the bolts. 4. Install the air cleaner outlet pipe. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor C180 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 2756 C1366 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 2757 C1367 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2758 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR Typical Synchronizer Hall-Effect CMP Sensor Typical Variable Reluctance CMP Sensor The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to select the correct ignition coil to fire. Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor and the 2-pin connector variable reluctance type sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2759 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation 1. Disconnect the camshaft position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. - To install, tighten to 6 Nm (53 lb-in). 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2763 Crankshaft Position Sensor: Diagrams C101 C1120 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2764 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Typical Crankshaft Position (CKP) Sensor The 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 PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L 10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor 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 a fixed reference for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid deceleration between teeth. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2765 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). 4. NOTE: Be sure the sensor wiring is routed away from the battery cable. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER Removal and Installation NOTE: - When any new lock cylinder is installed, the driver door and ignition lock cylinders should be installed as a set. This eliminates carrying an extra key which fits only 1 lock. If a new key is used, 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. With the ignition switch in the ON position, press the locking pin with a suitable tool and remove the ignition lock cylinder. 2. To install, reverse the removal procedure. - Lubricate the ignition lock cylinder during installation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2773 C108 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2774 Knock Sensor: Description and Operation KNOCK SENSOR (KS) Two Types Of Knock Sensor (KS) The KS 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2775 Knock Sensor: Service and Repair KNOCK SENSOR (KS) Removal and Installation 1. Remove the intake manifold. 2. Disconnect the knock sensor (KS) electrical connector. 3. Remove the bolt and the KS. - To install, tighten to 20 Nm (15 lb-ft). 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Item....................................................................................................................................................... ..............................................................Specification Fuel Pressure Key on, engine off................................................................................................................................. .............................................207-276 kPa (30-40 psi) Engine running................................................. ..................................................................................................................................207-276 kPa (30-40 psi) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Hot Idle Speed ..................................................................................................................................... ............................................................ 750-820 RPM Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair AIR CLEANER ELEMENT Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 2787 Exploded View Removal and Installation NOTE: Do not disconnect the mass air flow (MAF) sensor electrical connector. Vehicles equipped with a 4.0L (SOHC) engine 1. Detach the wiring harness retainer from the air cleaner outlet pipe. Vehicles equipped with a 4.6L (3V) engine Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 2788 2. Detach the wiring harness retainer from the coolant expansion tank. All vehicles 3. Loosen the clamp and disconnect the air cleaner outlet pipe from the air cleaner. 4. Unclip and remove the air cleaner cover. 5. Remove the air cleaner element. 6. NOTE: Clean the inside of the air cleaner tray. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE 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. - 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, which can cause a fire hazard. Failure to follow these instructions may result in personal injury. 1. NOTE: The front passenger door frame scuff plate is retained only by internal metal clips. Remove the front passenger door frame scuff plate. 2. NOTE: - The front passenger door side interior kick panel is retained only by internal metal clips. - It may be necessary to reposition the lower end of the door jam weather stripping to remove the front passenger door side interior kick panel. Remove the front passenger side interior kick panel. 3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Start the engine and allow it to idle until it stalls. 5. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail pressure has been released. 6. Turn the ignition switch to the OFF position. 7. When the fuel system service is complete, reconnect the IFS switch electrical connector. 8. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 9. Start the vehicle and check the fuel system for leaks. 10. Install the front passenger side interior kick panel. 11. Install the front passenger door frame scuff plate. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Item....................................................................................................................................................... ..............................................................Specification Firing order........................................................................................................................................... ..................................................................1-4-2-5-3-6 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > System Information > Specifications Ignition Timing: Specifications Item....................................................................................................................................................... ..............................................................Specification Base ignition timing.............................................................................................................................. ..............................10 degrees BTDC Non-adjustable Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair Ignition Cable: Service and Repair SPARK PLUG WIRES Exploded View Special Tool(s) Special Tool(s) Removal and Installation 1. CAUTION: It is important to twist the spark plug wire boot while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Page 2802 Squeeze the locking tabs and twist while pulling upward to disconnect the 6 spark plug wires from the ignition coil. 2. Detach the spark plug wires from the spark plug wire retainers. 3. CAUTION: It is important to twist the spark plug wire boot while pulling upward to avoid damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct spark plug. With a twisting motion, use the special tool to pull the spark plug wires from the spark plugs. 4. NOTE: Apply silicone dielectric compound to the inside of the spark plug wire boots. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > General Specifications Spark Plug: Specifications General Specifications Item....................................................................................................................................................... ..............................................................Specification Spark plug gap..................................................................................................................................... ....................................1.32-1.42 mm (0.052-0.056 in) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > General Specifications > Page 2807 Torque Specifications Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2808 Spark Plug: Application and ID SPARK PLUG TYPE LH ........................................................................................................................................................ .......................................................... AGSF24PM RH ....................................................................................................................................................... ........................................................ AGSF24PGM Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2809 Spark Plug: Testing and Inspection Spark Plug Inspection 1. Inspect the spark plug for a bridged gap. ^ Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or carbon fouling. ^ Clean the spark plug. 2. Check for oil fouling. ^ Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil entering the combustion chamber through worn rings and pistons, excessive valve-to-guide clearance or worn or loose bearings. ^ Correct the oil leak concern. ^ Install a new spark plug. 3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips, exposed shell surfaces and electrodes, caused by a spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive idling. ^ Clean the spark plug. 4. Inspect for normal burning. ^ Check for light tan or gray deposits on the firing tip. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2810 5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator. Metallic deposits on the insulator indicate engine damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized installation of a heli-coil insert in place of the spark plug threads. ^ Install a new spark plug. 6. Inspect for overheating, identified by white or light gray spots and with bluish-burnt appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing. ^ Install a new spark plug. 7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. ^ Clean the spark plug. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2811 Spark Plug: Service and Repair SPARK PLUGS Exploded View Special Tool(s) Removal and Installation Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2812 1. CAUTION: It is important to twist the spark plug wire boot while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct spark plug. With a twisting motion, use the special tool to pull the spark plug wire from the spark plug. 2. NOTE: Use compressed air to remove any foreign material from the spark plug wells before removing the spark plugs Remove the spark plugs. To install, tighten to 17 Nm (13 lb-ft). 3. Use a suitable spark plug gap tool to check and adjust the spark plug gap. 4. NOTE: Apply silicone dielectric compound to the inside of the spark plug wire boots. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 at least 75% of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Compression Pressure Limit Chart Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2816 Compression Check: Testing and Inspection Compression Test - Compression Gauge Check 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 5 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 at least 75% of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Compression Pressure Limit Chart If one or more cylinders read low, squirt approximately one tablespoon of engine oil 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. 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If 2 adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2817 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 at least 75% of the highest reading. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations View 151-11 (behind Dash Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2822 C2040 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2823 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The APP sensor is an input to the powertrain control module (PCM) and is used to determine the torque demand. There are 3 pedal position signals in the sensor. Signal 1, APPS1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, APPS2 and APPS3, both have a positive slope (increasing angle, increasing voltage). During normal operation APPS1 is used as the indication of pedal position by the strategy. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. There are 2 reference voltage circuits and 2 signal return circuits for the sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2827 C128 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2828 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW (MAF) SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT Sensor Wire Where Applicable) Terminals Typical Mass Air Flow (MAF) Sensor Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2829 Typical Drop-in Mass Air Flow (MAF) Sensor The 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 the ambient temperature as measured by a constant cold wire. The current required to maintain the temperature of the hot wire is proportional to the mass air 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. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Most MAF sensors have integrated bypass technology with an integrated intake air temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2830 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Disconnect the mass air flow (MAF) sensor electrical connector. 2. Remove the bolts and the MAF. - To install, tighten to 2 Nm (18 lb-in). 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2834 C128 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2835 Intake Air Temperature Sensor: Description and Operation INTAKE AIR TEMPERATURE (IAT) SENSOR Typical Stand-Alone/Non-Integrated Intake Air Temperature (IAT) Sensors Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into A Drop-in Or Flange-type MAF Sensor The IAT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance 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 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 air flow. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2836 The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Currently there are 2 design types of IAT sensors used, a stand-alone/non-integrated type and a integrated type. Both types function the same, however the integrated type is incorporated into the mass air flow (MAF) sensor instead of being a stand alone sensor. Supercharged vehicles use 2 IAT sensors. Both sensors are thermistor type devices and operate as described. One is located before the supercharger at the air cleaner for standard OBD/cold weather input, while a second sensor (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 spark and to help determine charge air cooler (CAC) efficiency. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Specifications Torque Specifications Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) Body Control Module: Service and Repair Driver Seat Module (DSM) DRIVER SEAT MODULE (DSM) Special Tool(s) Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 2842 Removal and Installation CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: Prior to the removal of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new DSM after installation. 1. Remove the driver seat. 2. Remove the 2 DSM screws. 3. Disconnect the electrical connectors and remove the DSM. 4. NOTE: Once the module is installed it is necessary to download the module configuration information from the scan tool into the new module. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 2843 Body Control Module: Service and Repair Smart Junction Box (Sjb) SMART JUNCTION BOX (SJB) Special Tool(s) Special Tool(s) Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 2844 Part 2 Removal NOTE: - The steps included in the SJB removal and installation procedure are critical to restoring the vehicle security and tire pressure monitoring systems to normal operation. A new SJB is delivered in manufacturing mode with 6 pre-set diagnostic trouble codes (DTCs) related to the tire pressure monitoring system. The presence of these DTCs requires the installation procedures be followed in order to clear the DTCs and enable normal SJB operations. - Prior to the removal of the SJB, it is necessary to upload the module configuration information to the diagnostic tool. This information must be downloaded to the new SJB after installation. 1. Remove the driver door scuff plate. 2. Position the LH door opening weather seal aside. 3. NOTE: While pulling the trim panel rearward, pull the hood release lever rearward in order for the release lever to slide through the trim panel. Remove the pushpin and the cowl side trim panel. 4. Remove the 2 bolts and the parking brake release handle. 5. Disconnect the parking brake switch electrical connector. 6. Release the hood release cable pushpin from the parking brake control bracket. 7. Release the harness clip from the parking brake cable housing. 8. NOTE: Rotating the parking brake control counterclockwise allows enough access to clear the instrument panel reinforcement. Remove the 3 bolts and position the parking brake control assembly under the brake pedal. 9. CAUTION: The lower side of the headlight switch bezel includes 2 tabs that slide down onto the instrument panel and may be broken if any prying force is exerted in the lower area of the bezel. Using a suitable tool, pry the mid-to-upper side of the headlight switch bezel away from the instrument panel, disconnect the 2 electrical connectors and position the bezel assembly aside. 10. If necessary, push the LH instrument panel side finish panel out and position it aside. 11. Through the headlight switch bezel opening, remove the 2 SJB bolts. 12. From under the instrument panel, remove the third SJB bolt. 13. NOTE: The SJB electrical connector levers must click into a fully released position before they can be removed and must click into a fully closed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 2845 (connected) position when installing. Pull the SJB down out of the 2 locating pins, disconnect the 5 electrical connectors and remove the SJB. Installation NOTE: When a new SJB is installed, all customer RKE transmitters may be required to program the RKE transmitters to the new SJB. 1. NOTE: The SJB electrical connector levers must click into a fully released position before they can be removed and must click into a fully closed (connected) position when installing. Position the SJB into the 2 locating pins and connect the 5 electrical connectors. 2. From under the instrument panel, install the SJB bolt. 3. Through the headlight switch bezel opening, install the 2 SJB bolts. 4. If necessary, install the LH instrument panel side finish panel. 5. Connect the 2 electrical connectors and install the headlight switch bezel assembly into the instrument panel. 6. Position the parking brake control assembly and install the 3 bolts. - Tighten to 20 Nm (15 lb-ft). 7. Install the harness clip on the parking brake cable housing. 8. Install the hood release cable pushpin into the parking brake control bracket. 9. Connect the parking brake switch electrical connector. 10. Position the parking brake release handle and install the 2 bolts. 11. Position the hood release lever assembly and install the bolt. 12. NOTE: While installing the trim panel, pull the hood release lever rearward in order for the release lever to slide through the trim panel. Position the cowl side trim panel and install the pushpin. 13. Position the LH door opening weather seal. 14. Install the driver door scuff plate. 15. NOTE: When successful, this step provides the calibration necessary for SJB operation and clears DTC B2477. The clearing of the DTC indicates the calibration data has been successfully downloaded to the SJB. Download the SJB configuration information from the diagnostic tool to the SJB. 16. NOTE: When successful, this step clears DTCs B2868, B2869, B2870 and B2871. The clearing of these DTCs indicates the SJB has recognized the tire pressure sensors during the training procedure. Train the tire pressure sensors. 17. Clear the DTCs. 18. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode, and to be sure there are no other concerns with the newly programmed SJB. Carry out the SJB on-demand self-test. 19. NOTE: If the module configuration upload/download is successful, then the RKE transmitters do not need to be reprogrammed to the vehicle. However, if the module configuration upload/download is unsuccessful and as-built data must be used to configure the module, then ALL of the customer's RKE transmitters must be reprogrammed to the vehicle. Program the RKE transmitters to the new SJB (if necessary). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Locations View 151-1 (Engine Compartment - 4.0L, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Locations > Page 2849 C278 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Description and Operation > Brake Pedal Position (BPP) Switch Brake Signal: Description and Operation Brake Pedal Position (BPP) Switch BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Description and Operation > Brake Pedal Position (BPP) Switch > Page 2852 Brake Signal: Description and Operation Brake Pedal Switch (BPS) Brake Deactivator Switch BRAKE PEDAL SWITCH (BPS) BRAKE DEACTIVATOR SWITCH The BPS, also called the brake deactivator switch, is for vehicle speed control deactivation. A normally closed switch supplies battery positive voltage (B+) to the PCM when the brake pedal is not applied. When the brake pedal is applied, the normally closed switch opens and power is removed from the PCM. On some applications the normally closed BPS, along with the normally open BPP switch, are used for a brake rationality test within the PCM. The PCM misfire monitor profile learn function may be disabled if a brake switch concern occurs. If one or both brake pedal inputs to the PCM is not changing states when they were expected to, a diagnostic trouble code (DTC) is set by the PCM strategy. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor C180 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 2858 C1366 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 2859 C1367 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2860 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR Typical Synchronizer Hall-Effect CMP Sensor Typical Variable Reluctance CMP Sensor The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to select the correct ignition coil to fire. Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor and the 2-pin connector variable reluctance type sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2861 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation 1. Disconnect the camshaft position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. - To install, tighten to 6 Nm (53 lb-in). 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Description and Operation Clutch Switch: Description and Operation CLUTCH PEDAL POSITION (CPP) SWITCH Typical Clutch Pedal Position (CPP) Switch The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine load. The PCM uses the load information for mass air flow and fuel calculations. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2868 C1064 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2869 Coolant Temperature Sensor/Switch (For Computer): Description and Operation ENGINE COOLANT TEMPERATURE (ECT) SENSOR Typical Thread Type ECT Sensor The ECT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance changes 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 PCM uses the ECT input for fuel control and for cooling fan control. There are 3 types of ECT sensors, threaded, push-in, and twist-lock. The ECT sensor is located in an engine coolant passage. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2870 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR Removal and Installation 1. Drain the cooling system. 2. Disconnect the engine coolant temperature (ECT) sensor electrical connector. 3. Remove the clip and the ECT sensor. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2874 Crankshaft Position Sensor: Diagrams C101 C1120 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2875 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Typical Crankshaft Position (CKP) Sensor The 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 PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L 10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor 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 a fixed reference for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid deceleration between teeth. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2876 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). 4. NOTE: Be sure the sensor wiring is routed away from the battery cable. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2882 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2883 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2884 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2885 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2886 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2887 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2888 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2889 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2890 Data Link Connector: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2891 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2892 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2893 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2894 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2895 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2896 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2897 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2898 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2899 C251 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations > Page 2903 C1368 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations > Page 2904 Electronic Throttle Actuator: Description and Operation ELECTRONIC THROTTLE ACTUATOR CONTROL (TAC) The electronic TAC is a DC motor controlled by the PCM (requires 2 wires). The gear ratio from the motor to the throttle plate shaft is 17:1. There are 2 designs for the TAC, parallel and in-series. The parallel design has the motor under the bore parallel to the plate shaft. The motor housing is integrated into the main housing. The in-series design has a separate motor housing. Two springs are used; one is used to close the throttle (main spring) and the other is in a plunger assembly that results in a default angle when no power is applied. The force of the plunger spring is 2 times stronger than the main spring. The default angle is usually set to result in a top vehicle speed of 48 km/h (30 mph). Typically this throttle angle is 7 to 8 degree from the hard stop angle. The closed throttle plate hard stop is used to prevent the throttle from binding in the bore (~ 0.75 degree). This hard stop setting is not adjustable and is set to result in less airflow than the minimum engine airflow required at idle. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation Electronic Throttle Control Module: Description and Operation TORQUE BASED ELECTRONIC THROTTLE CONTROL (ETC) Overview The torque based ETC is a hardware and software strategy that delivers an engine output torque (via throttle angle) based on driver demand (pedal position). It uses an electronic throttle body, the powertrain control module (PCM), and an accelerator pedal assembly to control the throttle opening and engine torque. The ETC system replaces the standard cable operated accelerator pedal, idle air control (IAC) valve, 3-wire throttle position (TP) sensor, and mechanical throttle body. Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque during shifts, and by calculating this desired torque, the system prevents engine lugging (low RPM and low manifold vacuum) while still delivering the performance and torque requested by the driver. It also enables many fuel economy/emission improvement technologies such as variable camshaft timing (VCT) (deliver same torque during transitions). Torque based ETC also results in less intrusive vehicle and engine speed limiting, along with smoother traction control. Other benefits of ETC are: eliminate cruise control actuators - eliminate idle air control (IAC) valve - better airflow range - packaging (no cable) - more responsive powertrain at altitude and improved shift quality It should be noted that the ETC system illuminates a powertrain malfunction indicator (wrench) on the instrument cluster when a concern is present. Concerns are accompanied by diagnostic trouble codes (DTCs) and may also illuminate the malfunction indicator lamp (MIL). Electronic Throttle Body (ETB) The ETB has the following characteristics: 1. The throttle actuator control (TAC) motor is a DC motor controlled by the PCM (requires 2-wires). The gear ratio from the motor to the throttle plate shaft is 17:1. 2. There are 2 designs: parallel and in-series. The parallel design has the motor under the bore parallel to the plate shaft. The motor housing is integrated into the main housing. The in-series design has a separate motor housing. 3. Two springs are used: one is used to close the throttle (main spring) and the other is in a plunger assembly that results in a default angle when no power is applied. This is for limp home reasons (the force of the plunger spring is 2 times stronger than the main spring). The default angle is usually set to result in a top vehicle speed of 48 km/h (30 mph). Typically this throttle angle is 7 to 8 degrees from the hard-stop angle. 4. The closed throttle plate hard stop is used to prevent the throttle from binding in the bore (~0.75 degree). This hard stop setting is not adjustable and is set to result in less airflow than the minimum engine airflow required at idle. 5. Unlike cable operated throttle bodies, the intent for the ETB is not to have a hole in the throttle plate or to use plate sealant. The hole is not required in the ETB because the required idle airflow is provided by the plate angle in the throttle body assembly. This plate angle controls idle, idle quality, and eliminates the need for an IAC valve. 6. The TP sensor has 2 signal circuits in the sensor for redundancy. The redundant throttle position signals are required for increased monitoring reasons. The first TP signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). During normal operation the negative slope TP signal (TP1) is used by the control strategy as the indication of throttle position. The TP sensor assembly requires 4 circuits. 5-volt reference voltage - Signal return (ground) - TP1 voltage with negative voltage slope (5-0 volts) - TP2 voltage with positive voltage slope (0-5 volts) Accelerator Pedal Position (APP) Sensors Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2908 Electronic Throttle Body (ETB) And Accelerator Pedal Assembly The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1. There are 3 pedal position signals required for system monitoring. APP1 has a negative slope (increasing angle, decreasing voltage) and APP2 and APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. 2. There are 2 VREF circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. 2 reference voltage circuits (5 volts) - 2 signal return (ground) circuits - APP1 voltage with negative voltage slope (5-0 volts) - APP2 voltage with positive voltage slope (0-5 volts) - APP3 voltage with positive voltage slope (0-5 volts) 3. The pedal position signal is convened to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. 4. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. A value is substituted for an incorrect signal if 2 of the 3 signals are incorrect. Electronic Throttle Control (ETC) System Strategy Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2909 ETC System The torque based ETC strategy was developed to improve fuel economy and to accommodate variable camshaft timing (VCT). This is possible by not coupling the throttle angle to the driver pedal position. Uncoupling the throttle angle (produce engine torque) from the pedal position (driver demand) allows the powertrain control strategy to optimize fuel control and transmission shift schedules while delivering the requested wheel torque. The ETC monitor system is distributed across 2 processors within the PCM: the main powertrain control processor unit (CPU) and a monitoring processor called an enhanced-quizzer (E-Quizzer) processor. The primary monitoring function is carried out by the independent plausibility check (IPC) software, which resides on the main processor. It is responsible for determining the driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the generated torque exceeds driver demand by a specified amount, the IPC takes appropriate corrective action. ETC System Failure Mode And Effects Management (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2910 ETC System Failure Mode And Effects Management (Part 2) Since the IPC and the main controller share the same processor, they are subject to a number of potential common failure modes. The E-Quizzer processor was added to redundantly monitor selected PCM inputs and to act as an intelligent watchdog and monitor the performance of the IPC and the main processor. If it determines that the IPC function is impaired in any way, it takes appropriate failure mode and effects management (FMEM) actions. Electronic Throttle Monitor Operation: Electronic Throttle Monitor Operation (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2911 Electronic Throttle Monitor Operation (Part 2) Accelerator and Throttle Position (TP) Sensor Inputs Accelerator Pedal Position (APP) Sensor Check: Accelerator Pedal Position (APP) Sensor Check Throttle Position (TP) Sensor Check: Throttle Position (TP) Sensor Check Throttle Plate Position Controller (TPPC) Outputs Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2912 Throttle Plate Controller Check Operation The purpose of the TPPC is to maintain the throttle position at the desired throttle angle. It is a separate chip embedded in the PCM. The desired angle is communicated from the main CPU via a 312.5 Hz duty cycle (DC) signal. The TPPC interprets the duty cycle signal as follows: Less than 4% - Out of range, limp home default position. - Greater than or equal to 4% but less than 6% - Commanded default position, closed. - Greater than or equal to 6% but less than 7% - Commanded default position. Used for key ON, engine OFF. - Greater than or equal to 7% but less than 8% - Enable ice breaker mode. Used to clear potential ice buildup in the throttle body. - Greater than or equal to 8% but less than 10% - Closed against hard-stop. Used to learn zero throttle angle position (hard stop) after key-up. - Greater than or equal to 10% but less than or equal to 92% - Normal operation, between 0 degrees (hard stop) and 82 degrees, 10% duty cycle equals 0 degrees throttle angle, 92% duty cycle equals 82 degrees throttle angle. - Greater than 92% but less than or equal to 96% - Wide open throttle, 82 to 86 degrees throttle angle. - Greater than 96% but less than or equal to 100% - Out of range, limp home default position. The desired angle is relative to the hard-stop angle. The hard stop angle is learned during each key-up process before the main CPU requests the throttle plate be closed against the hard stop. The output of the TPPC is a voltage request to the H driver (also in PCM). The H driver is capable of positive or negative voltage to the electronic throttle body motor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start Engine Control Module: Customer Interest Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start TSB 08-18-2 09/15/08 MIL ON - P0506 AND/OR P0505 - HESITATION/LOSS OF RPM/DIFFICULTY STARTING/LOW IDLE RPM FORD: 2005-2007 Crown Victoria 2006 Mustang, Mustang 2004-2006 F-150, F-150 2005-2006 E-350, E-450, F-Super Duty 2006 F-53 Motorhome Chassis 2006-2007 Explorer Sport Trac, Explorer LINCOLN: 2005-2007 Town Car 2006 Mark LT MERCURY: 2005-2007 Grand Marquis 2006-2007 Mountaineer, Mountaineer This article supersedes TSB(s) 08-5-13, 07-23-12 and 06-25-8 to update the Service Procedure. ISSUE Some 2004-2006 4.6L and 5.4L F-150 (excluding F-150 Heritage), 2006 5.4L Mark LT, 2005-2006 6.8L E-350 / E-450, 2005-2006 6.8L F-Super Duty (F-250 to F-550), 2006 6.8L F-53 Motorhome Chassis, 2006-2007 4.0L Explorer 4 dr, 2007 4.0L Explorer Sport Trac, 2006-2007 4.0L Mountaineer, 2006 4.0L Mustang, 2006 - 2007 4.6L 3V Explorer / Explorer Sport Trac / Mountaineer, 2006 4.6L 3V Mustang, and 2005-2007 Crown Vic / Grand Marquis / Towncar vehicles may exhibit one or more of the following symptoms: drive-away hesitation, loss of RPM on deceleration, difficulty starting, and/or idle RPM less than desired. Malfunction indicator lamp (MIL) may be illuminated with diagnostic trouble codes (DTCs) P0506 and/or P0505. These conditions may appear after battery disconnect, dead battery condition, or keep alive memory (KAM) reset. The symptoms may be due to engine deposits in the throttle leading to air[low less than desired. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 53.9 and higher or 54.1 and higher. This new calibration is not included in the VCM 2008.1 DVD. Calibration files may also be obtained at the website. The calibration contains a sludge compensation strategy for the throttle body. 2. Turn the key off to re-initialize the PCM. This will allow the sludge compensation strategy to learn. 3. With the vehicle in park or neutral and A/C off, start vehicle and allow engine to reach normal operating temperature(greater than 170 °F (77 °C) coolant temperature). Run an additional 5 minutes to allow sufficient learning time. 4. While the engine is running, using IDS datalogger or equivalent, check the PID value of ETC_TRIM. a. If ETC_TRIM value is 3.5 degrees, and/or DTC PuSE is present, then replace the electronic throttle body (ETB), following Workshop Manual (WSM), Section 303-04B. b. If ETC_TRIM value is less than 3.5 degrees and DTC PuSE is not present, but driveability concerns persist, the ETB is not the likely cause of the concern and replacement is not necessary. Continue with normal PC/ED diagnostics. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start > Page 2921 NOTE VEHICLES EQUIPPED WITH A PCM AND TCM REQUIRE COORDINATED REPROGRAMMING. THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS OUTLINED BY THE IDS. FAILURE TO FOLLOW THE KEY CYCLE PROCEDURE WITHOUT WAITING FOR THE IDS PROMPTS, WILL CAUSE THE COORDINATED REPROGRAMMING TO FAIL. THE PCM WILL BE UPDATED BUT THE 1CM WILL NOT BE UPDATED AND NEW FILES WILL NOT BE INSTALLED. IT IS CRITICAL TO FOLLOW THE IDS PROMPTS. SOME VEHICLES MAY REQUIRE SEVERAL DAYS OF DRIVING FOR THE TRANSMISSION TO FULLY ADAPT. REPROGRAMMING CONCERNS/ERRORS MAY BE CAUSED BY THE DATA LINK CONNECTOR (DLC) OR VEHICLE COMMUNICATION MODULE (VCM) BECOMING DISCONNECTED, LOW BATTERIES ON THE INTEGRATED DIAGNOSTIC SYSTEM (IDS) OR THE IDS GOING INTO ANY TYPE OF SLEEP MODE, OR LOW VEHICLE BATTERY VOLTAGE. IF THERE WAS AN INTERRUPTION DURING REPROGRAMMING, MAKE SURE THE ORIGINAL IDS SESSION THAT WAS CREATED FOR THE VEHICLE IS NOT DELETED. IF THE ORIGINAL VEHICLE SESSION IS NOT USED OR DELETED BEFORE THE MODULES ARE COMPLETELY REPROGRAMMED, FURTHER REPROGRAMMING ERRORS CAN OCCUR. THE MODULE RECOVERY PROCEDURE IS NO LONGER AVAILABLE AND IT IS CRITICAL THAT MODULE SWAPPING IS NOT PERFORMED FROM VEHICLE TO VEHICLE. TO REGAIN COMMUNICATION WITH A MODULE THAT HAS BEEN ERASED DURING REPROGRAMMING, RESUME THE ORIGINAL SESSION ONCE THE IDS IS RE-BOOTED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081802A 2004-2006 F-150 0.4 Hr. 4.6L/5.4L, 2006 Mark LT, Econoline 350/450 6.8L 2005-2006 F-Super Duty 6.8L, 2006-2007 Explorer/Mountaineer 4.0L, 2007 Explorer Sport Trac 4.0L, 2006 Mustang 4.OL, 2005-2007 Crown Victoria, Town Car, Grand Marquis: Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Authorization Decal NOT Necessary. (Do Not Use With 9926A, 12650D) 081802A 2006-2007 1.0 Hr. Explorer/Mountaineer 4.6L, 2007 Explorer Sport Trac 4.6L: Check For DICs And Reprogram The PCM And 1CM, Includes Time To Monitor ETC_Trim Value, Authorization Decal NOT Necessary. (Do Not Use With 9926A, 12650D) 081802B 2004-2006 F-150 5.4L, 0.9 Hr. 2006 Mark LT: Check For DTCs And Reprogram The PCM, Includes Time To Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start > Page 2922 Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2004-2006 F-150 4.6L: 0.8 Hr. Check For DTCs And Reprogram The PCM Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2005-2006 Econoline 6.8L: 1.1 Hrs. Check For DTCs And Reprogram The PCM Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2005-2006 F-Super Duty 0.9 Hr. 6.8L: Check For DTCs And Reprogram The PCM Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2006-2007 Explorer, 1.4 Hrs. Mountaineer 2007 Explorer Sport Trac 4.6L: Check For DTCs And Reprogram The PCM And TCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2006-2007 Explorer, 0.8 Hr. Mountaineer 2007 Explorer Sport Trac 4.0L: Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2005-2007 Crown Victoria, 0.8 Hr. Town Car, Grand Marquis: Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start > Page 2923 Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2006 Mustang 4.0L/4.6L: 0.8 Hr. Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start TSB 08-18-2 09/15/08 MIL ON - P0506 AND/OR P0505 - HESITATION/LOSS OF RPM/DIFFICULTY STARTING/LOW IDLE RPM FORD: 2005-2007 Crown Victoria 2006 Mustang, Mustang 2004-2006 F-150, F-150 2005-2006 E-350, E-450, F-Super Duty 2006 F-53 Motorhome Chassis 2006-2007 Explorer Sport Trac, Explorer LINCOLN: 2005-2007 Town Car 2006 Mark LT MERCURY: 2005-2007 Grand Marquis 2006-2007 Mountaineer, Mountaineer This article supersedes TSB(s) 08-5-13, 07-23-12 and 06-25-8 to update the Service Procedure. ISSUE Some 2004-2006 4.6L and 5.4L F-150 (excluding F-150 Heritage), 2006 5.4L Mark LT, 2005-2006 6.8L E-350 / E-450, 2005-2006 6.8L F-Super Duty (F-250 to F-550), 2006 6.8L F-53 Motorhome Chassis, 2006-2007 4.0L Explorer 4 dr, 2007 4.0L Explorer Sport Trac, 2006-2007 4.0L Mountaineer, 2006 4.0L Mustang, 2006 - 2007 4.6L 3V Explorer / Explorer Sport Trac / Mountaineer, 2006 4.6L 3V Mustang, and 2005-2007 Crown Vic / Grand Marquis / Towncar vehicles may exhibit one or more of the following symptoms: drive-away hesitation, loss of RPM on deceleration, difficulty starting, and/or idle RPM less than desired. Malfunction indicator lamp (MIL) may be illuminated with diagnostic trouble codes (DTCs) P0506 and/or P0505. These conditions may appear after battery disconnect, dead battery condition, or keep alive memory (KAM) reset. The symptoms may be due to engine deposits in the throttle leading to air[low less than desired. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 53.9 and higher or 54.1 and higher. This new calibration is not included in the VCM 2008.1 DVD. Calibration files may also be obtained at the website. The calibration contains a sludge compensation strategy for the throttle body. 2. Turn the key off to re-initialize the PCM. This will allow the sludge compensation strategy to learn. 3. With the vehicle in park or neutral and A/C off, start vehicle and allow engine to reach normal operating temperature(greater than 170 °F (77 °C) coolant temperature). Run an additional 5 minutes to allow sufficient learning time. 4. While the engine is running, using IDS datalogger or equivalent, check the PID value of ETC_TRIM. a. If ETC_TRIM value is 3.5 degrees, and/or DTC PuSE is present, then replace the electronic throttle body (ETB), following Workshop Manual (WSM), Section 303-04B. b. If ETC_TRIM value is less than 3.5 degrees and DTC PuSE is not present, but driveability concerns persist, the ETB is not the likely cause of the concern and replacement is not necessary. Continue with normal PC/ED diagnostics. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start > Page 2929 NOTE VEHICLES EQUIPPED WITH A PCM AND TCM REQUIRE COORDINATED REPROGRAMMING. THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS OUTLINED BY THE IDS. FAILURE TO FOLLOW THE KEY CYCLE PROCEDURE WITHOUT WAITING FOR THE IDS PROMPTS, WILL CAUSE THE COORDINATED REPROGRAMMING TO FAIL. THE PCM WILL BE UPDATED BUT THE 1CM WILL NOT BE UPDATED AND NEW FILES WILL NOT BE INSTALLED. IT IS CRITICAL TO FOLLOW THE IDS PROMPTS. SOME VEHICLES MAY REQUIRE SEVERAL DAYS OF DRIVING FOR THE TRANSMISSION TO FULLY ADAPT. REPROGRAMMING CONCERNS/ERRORS MAY BE CAUSED BY THE DATA LINK CONNECTOR (DLC) OR VEHICLE COMMUNICATION MODULE (VCM) BECOMING DISCONNECTED, LOW BATTERIES ON THE INTEGRATED DIAGNOSTIC SYSTEM (IDS) OR THE IDS GOING INTO ANY TYPE OF SLEEP MODE, OR LOW VEHICLE BATTERY VOLTAGE. IF THERE WAS AN INTERRUPTION DURING REPROGRAMMING, MAKE SURE THE ORIGINAL IDS SESSION THAT WAS CREATED FOR THE VEHICLE IS NOT DELETED. IF THE ORIGINAL VEHICLE SESSION IS NOT USED OR DELETED BEFORE THE MODULES ARE COMPLETELY REPROGRAMMED, FURTHER REPROGRAMMING ERRORS CAN OCCUR. THE MODULE RECOVERY PROCEDURE IS NO LONGER AVAILABLE AND IT IS CRITICAL THAT MODULE SWAPPING IS NOT PERFORMED FROM VEHICLE TO VEHICLE. TO REGAIN COMMUNICATION WITH A MODULE THAT HAS BEEN ERASED DURING REPROGRAMMING, RESUME THE ORIGINAL SESSION ONCE THE IDS IS RE-BOOTED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081802A 2004-2006 F-150 0.4 Hr. 4.6L/5.4L, 2006 Mark LT, Econoline 350/450 6.8L 2005-2006 F-Super Duty 6.8L, 2006-2007 Explorer/Mountaineer 4.0L, 2007 Explorer Sport Trac 4.0L, 2006 Mustang 4.OL, 2005-2007 Crown Victoria, Town Car, Grand Marquis: Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Authorization Decal NOT Necessary. (Do Not Use With 9926A, 12650D) 081802A 2006-2007 1.0 Hr. Explorer/Mountaineer 4.6L, 2007 Explorer Sport Trac 4.6L: Check For DICs And Reprogram The PCM And 1CM, Includes Time To Monitor ETC_Trim Value, Authorization Decal NOT Necessary. (Do Not Use With 9926A, 12650D) 081802B 2004-2006 F-150 5.4L, 0.9 Hr. 2006 Mark LT: Check For DTCs And Reprogram The PCM, Includes Time To Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start > Page 2930 Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2004-2006 F-150 4.6L: 0.8 Hr. Check For DTCs And Reprogram The PCM Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2005-2006 Econoline 6.8L: 1.1 Hrs. Check For DTCs And Reprogram The PCM Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2005-2006 F-Super Duty 0.9 Hr. 6.8L: Check For DTCs And Reprogram The PCM Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2006-2007 Explorer, 1.4 Hrs. Mountaineer 2007 Explorer Sport Trac 4.6L: Check For DTCs And Reprogram The PCM And TCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2006-2007 Explorer, 0.8 Hr. Mountaineer 2007 Explorer Sport Trac 4.0L: Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2005-2007 Crown Victoria, 0.8 Hr. Town Car, Grand Marquis: Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start > Page 2931 Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2006 Mustang 4.0L/4.6L: 0.8 Hr. Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2937 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2938 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2944 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2945 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2946 Engine Control Module: Locations View 151-1 (Engine Compartment - 4.0L, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2947 View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2950 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2951 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2952 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2953 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2954 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2955 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2956 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2957 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2958 Engine Control Module: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2959 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2960 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2961 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2962 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2963 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2964 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2965 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2966 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2967 Engine Control Module: Connector Views C175B (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2968 C175B (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2969 C175E (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2970 C175E (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2971 C175T (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2972 C175T (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) Engine Control Module: Service and Repair Powertrain Control Module (PCM) POWERTRAIN CONTROL MODULE (PCM) Removal All vehicles 1. NOTE: Powertrain control module (PCM) installation DOES NOT require new keys. Retrieve the module configuration. Carry out the module configuration retrieval steps of the Programmable Module Installation procedure. Vehicles equipped with a 4.6L (3V) engine 2. Remove the air cleaner. All vehicles Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) > Page 2975 3. Disconnect the RH front wheel speed sensor electrical connector. Remove the nuts and position the A/C tube brackets and wiring harness aside. 4. Disconnect the PCM connectors. 5. Remove the bolts and the PCM. Installation All vehicles 1. Install the PCM and bolts. - Tighten to 10 Nm (89 lb-in). 2. Connect the PCM electrical connectors. 3. Position the wiring harness and the A/C tube brackets and install the nuts. Connect the RH front wheel speed sensor electrical connector. - Tighten to 7 Nm (62 lb-in). Vehicles equipped with a 4.6L (3V) engine 4. Install the air cleaner. All vehicles 5. Restore the module configuration. Carry out the module configuration restore steps of the Programmable Module Installation procedure. 6. Reprogram the passive anti-theft system (PATS). Carry out the Parameter Reset procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) > Page 2976 Engine Control Module: Service and Repair Flash Electrically Erasable Programmable Read Only Memory (EEPROM) FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) Description The 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 programmed or flashed repeatedly. As part of the calibration there is an area referred to as the vehicle identification (VID) block. The VID block is programmed when installing a new PCM as described under Programming the VID Block for a Replacement PCM. Failure to carry out this procedure may generate DTCs P1635 or P1639. The VID block in an existing PCM can also be tailored to accommodate various hardware or parameter changes made to the vehicle since production. Failure to carry out this procedure properly may generate DTC P1635, Tire/Axle Ratio out of Acceptable Range. An incorrect tire/axle ratio is one of the main causes for DTC P1639. 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 vehicle identification number (VIN), octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control, and 4-wheel drive electronic shift-on-the-fly (ESOF) versus manual shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported by the VID block is displayed on the scan tool. When changing items in the VID block, the strategy places range limits on certain items such as tire and axle ratio. The number of times the VID block may be reconfigured is limited. When this limit is reached, the scan tool displays a message indicating the need to flash the PCM again to reset the VID block. Programming can be carried out by a local Ford dealer or any non-Ford facility. Refer to the scan tool manufacturer's instruction manual for details. Programming the VID Block for a Replacement PCM A new PCM contains the latest strategy and calibration level for a particular vehicle. However, the VID block is blank and needs programming. There are 2 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 is carried out if the old PCM is capable of communicating. This is done by using a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can then be downloaded to the new PCM after it has been installed. Carry out manual data entry if the old module is damaged or incapable of communicating. Remove and install a new PCM. Using a compatible scan tool, select and carry out the module/parameter programming, referring to the scan tool manufacturer's instruction manual. Make certain that all parameters are included. Failure to properly program tire size in revolutions per mile, (rev/mile equals 63,360 divided by the tire circumference in inches), axle ratio, 4x4/4x2, and/or MSOF/ESOF may result in DTCs P1635 and P1639. 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 and Lincoln Mercury technicians, contact your National Hotline or the Professional Technician Society (PTS) website for As-Built data listed under the Service Publications Index. Non-Ford technicians use the Motorcraft(R) website at www.motorcraft.com. From the Motorcraft(R) homepage, use the search function to find the Module Programming or As-Built Data. For Ford and Lincoln Mercury technicians, check the Programmable Module Installation link on the PTS website for quick Programmable Module data information by vehicle. Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate the vehicle hardware. Refer to Module Reprogramming on the scan tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM needs 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 Module Reprogramming on the scan tool. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Diagrams C107 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Diagrams > Page 2980 Engine Temperature Sensor: Description and Operation CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical CHT Sensor The CHT sensor is a thermistor device in which resistance changes with the temperature. The electrical resistance of a thermistor decreases as temperature increases., and the resistance 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. The CHT sensor is installed in the 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 initiates a fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern 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. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations View 151-14 (Right Front) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2984 Fuel Level Sensor: Diagrams C434A C434B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2985 Fuel Level Sensor: Description and Operation FUEL LEVEL INPUT (FLI) The FLI is a communications network message. Most vehicle applications use a potentiometer type FLI sensor connected to a float in the FP module to determine fuel level. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2986 Fuel Level Sensor: Service and Repair FUEL LEVEL SENSOR Explorer Sport Trac (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2987 Explorer Sport Trac (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2988 Explorer/Mountaineer (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2989 Explorer/Mountaineer (Part 2) All Vehicles (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2990 All Vehicles (Part 2) Removal 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. 1. Remove the fuel pump. 2. NOTE: Note the routing of the sending unit wire for installation. Remove the heat shrink tube covering the electrical connector. 3. Disconnect the electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2991 4. Remove the screw and lift up to remove the fuel gauge sending unit. Installation 1. Route the fuel gauge sending unit wire through the center of the fuel pump module. 2. NOTE: - Both fuel gauge sending wires must be routed behind the metal sending unit plate. - The grounding eyelet must be on the front side of the sending unit. Hook the fuel gauge sending unit on the fuel pump module and install the screw through the grounding eyelet and tighten the screw. 3. Slide the heat shrink tube onto the wire harness and connect the electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2992 4. WARNING: Do not use an open flame to shrink the heat shrink tube, use a heat gun only. Failure to follow these instructions may result in personal injury. Using a heat gun, shrink the heat shrink tube. 5. Install the fuel pump. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE (FTP) SENSOR Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The FTP sensor or in-line FTP sensor is used to measure the fuel tank pressure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Page 2996 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR Removal and Installation WARNING: - The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not present in large quantities, it still presents a danger or 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 cause 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. 1. Remove the evaporative emission (EVAP) canister. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Page 2997 2. Remove the fuel tank shield from the fuel tank. 3. Disconnect the fuel tank pressure sensor electrical connector. 4. Disconnect the 3 fuel tank pressure sensor and tube assembly quick connect couplings from the fuel pump module and the vapor vent valves. 5. Remove the fuel tank pressure sensor and tube assembly. 6. To install, reverse the removal procedure. 7. Leak test the evaporative emission system. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Evaporative Emission System Leak Test 8. Carry out the evaporative emission repair verification drive cycle. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Evaporative Emission Repair Verification Drive Cycle Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation Idle Speed/Throttle Actuator - Electronic: Description and Operation IDLE AIR CONTROL (IAC) VALVE NOTE: The IAC valve assembly is not adjustable and cannot be cleaned, also some IAC valves are normally open and others are normally closed. Some IAC valves require engine vacuum to operate. The IAC valve assembly controls the 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. 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 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3005 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3006 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3007 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3008 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3009 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3010 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3011 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3012 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3013 Information Bus: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3014 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3015 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3016 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3017 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3018 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3019 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3020 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3021 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3022 Information Bus: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 14-5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3023 14-6 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. See: Diagrams/Components/Component Location Views Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 3024 Information Bus: Description and Operation COMMUNICATIONS NETWORK Vehicle communication utilizes both medium and high speed controller area network (CAN) communications. CAN is used for many modules to communicate with each other on a common network. CAN in-vehicle networking, is a method for transferring data among distributed electronic modules via a serial data bus. Without serial networking, intermodule communication requires dedicated, point to point wiring resulting in bulky, expensive, complex, and difficult to install wiring harnesses. Applying a serial data network reduces the number of wires combining the signals on a single network. Information is sent to the individual control modules that control each function. The vehicle has 2 module communication networks: - Medium speed (MS) CAN - High speed (HS) CAN Both networks are connected to the data link connector (DLC). This makes diagnosis and testing of these systems easier by allowing one scan tool to be able to diagnose and control any module on both networks from one connector. The DLC can be found under the instrument panel between the steering column and the audio unit. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 3025 Network Topology MS-CAN Network Operation The MS-CAN network communicates using bussed messages. The MS-CAN has an unshielded twisted pair cable, data bus (+) and data bus (-) circuits. In addition to scan tool communication, this network allows sharing of information between all modules on the network. The MS-CAN is a medium speed communication network used for the following modules: SJB - Audio unit - Instrument cluster - DSM (if equipped) - DVD player (if equipped) - EATC module (if equipped) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 3026 - Parking aid module (if equipped) - Satellite audio receiver (if equipped) - Power running board module (if equipped) HS-CAN Network Operation The HS-CAN network communicates using bussed messages. The HS-CAN network uses an unshielded twisted pair cable, data bus (+) and data bus (-) circuits. In addition to scan tool communication, this network allows sharing of information between all modules on the network. The HS-CAN is a high speed communication network used for the following modules: PCM - TCM (if equipped) - RCM - ABS module - Instrument cluster - Occupant classification sensor module - 4WD control module (if equipped) Network Termination The CAN network uses a network termination circuit to improve communication reliability. The network termination of the CAN bus takes place inside the termination modules by termination resistors. Termination modules are located at either end of the bus network. As network messages are broadcast in the form of voltage signals, the network voltage signals are stabilized by the termination resistors. Each termination module has a 120ohm resistor across the positive and negative bus connection in the termination module. With 2 termination modules on each network, and the 120 ohm resistors located in a parallel circuit configuration, the total network impedance, or total resistance is 60 ohms. Network termination improves bus message reliability by: stabilizing bus voltage. - eliminating electrical interference. Gateway Module The instrument cluster is the gateway module, translating HS-CAN to MS-CAN and vice versa. This information allows a message to be distributed throughout both networks. The instrument cluster is the only module on this vehicle that has this ability. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Information Bus: Initial Inspection and Diagnostic Overview Inspection and Verification INSPECTION AND VERIFICATION 1. Verify the customer concern. 2. Visually inspect the following for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical Battery junction box (BJB) fuse(s): 3 (50A) (no communication with smart junction box [SJB]) - 6 (40A) (no communication with anti-lock brake system [ABS] module) - 19 (30A) (no communication with power running board module) - 23 (20A) (no communication with four wheel drive [4WD] control module) - 24 (10A) (no communication with powertrain control module [PCM]) - 26 (20A) (no communication with 4WD control module) - 27 (20A) (no communication with transmission control module [TCM]) - 33 (30A) (no communication with ABS module) - 39 (15A) (no communication with PCM) - 41 (15A) (no communication with satellite radio receiver, digital versatile disc [DVD]) - Smart junction box (SJB) fuse(s): 1 (20A) (no communication with driver seat module [DSM]) - 2 (5A) (no communication with SJB) - 3 (20A) (no communication with audio unit) - 4 (20A) (no power to scan tool) - 8 (15A) (no communication with instrument cluster) - 9 (2A) (no communication with TCM) - 12 (5A) (no communication with audio unit) - 17 (10A) (no communication with restraints control module [RCM], occupant classification sensor module) - 18 (10A) (no communication with ABS module, 4WD control module, parking aid module) - 20 (10A) (no communication with electronic automatic temperature control [EATC]) module - 24 (10A) (no communication with instrument cluster) - 28 (10A) (no communication with EATC module) - Data link connector (DLC) - Wiring harness - Circuitry 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. NOTE: Make sure to use the latest scan tool software release. If the cause is not visually evident, connect the scan tool to the DLC. NOTE: The vehicle communication module (VCM) LED prove-out confirms power and ground from the DLC are provided to the VCM. If the scan tool does not communicate with the VCM: Check the VCM connection to the vehicle. - Check the scan tool connection to the VCM. - GO to Pinpoint Test R, to diagnose no power to the scan tool. See: Pinpoint Tests/Test R: No Power to the Scan Tool 5. NOTE: During the network test, the scan tool will first attempt to communicate with the PCM, after establishing communication with the PCM, the scan tool will then attempt to communicate with all other modules on the vehicle. Carry out the network test: If the network test passes, retrieve and record the continuous memory DTCs and proceed to Step 6. - If the network test fails, GO to Symptom Chart to identify the module not communicating. See: Symptom Related Diagnostic Procedures 6. If the DTCs retrieved are related to the concern, go to the Communication Network Diagnostic Trouble Code (DTC) Chart. For all other DTCs, refer to Body Control Systems (Multifunction Electronic Control Module). See: Diagnostic Trouble Code Descriptions/Module Communications Network 7. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Principles of Operation Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3029 PRINCIPLES OF OPERATION Vehicle communication utilizes both medium and high speed controller area network (CAN) communications. CAN is a method for transferring data among distributed electronic modules via a serial data bus. The vehicle is equipped with 2 module communication networks: - Medium speed (MS) CAN - High speed (HS) CAN MS-CAN The MS-CAN is a medium speed communication network that uses an unshielded twisted pair cable of data (+) and data (-) circuits. The data (+) and the data (-) circuits are each regulated to approximately 2.5 volts during neutral or rested network traffic. As bus messages are sent on the data (+) circuit, voltage is increased by approximately 1.0 volt. Inversely, the data (-) circuit is reduced by approximately 1.0 volt when a bus message is sent. Multiple bus messages can be sent over the network CAN circuits allowing multiple modules to communicate with each other. The MS-CAN network will not communicate while certain faults are present, but will operate with diminished performance with other faults present. The MS-CAN network may remain operational when 1 of the 2 termination resistors are not present. The MS-CAN network operates at a maximum data transfer speed of 125 Kbps for bus messages and designed for general information transfer. The network will remain operational, but at a degraded level, when certain circuit faults are present. The following modules are on the MS-CAN network: Audio unit - Instrument cluster - Smart junction box (SJB) - Parking aid module (if equipped) - Driver seat module (if equipped - Satellite radio receiver (if equipped) - Power running board module (if equipped) - Digital versatile disc (DVD) player (if equipped) - Electronic automatic temperature control (EATC) module (if equipped) MS-CAN Network Communication Fault Chart The fault chart describes the specific MS-CAN network failures and their resulting symptom: HS-CAN The HS-CAN is a high speed communication network that uses an unshielded twisted pair cable of data (+) and data (-) circuits. The data (+) and the data (-) circuits are each regulated to approximately 2.5 volts during neutral or rested network traffic. As bus messages are sent on the data (+) circuit, voltage is increased by approximately 1.0 volt. Inversely, the data (-) circuit is reduced by approximately 1.0 volt when a bus message is sent. Multiple bus messages can be sent over the network CAN circuits allowing multiple modules to communicate with each other. The HS-CAN network will not communicate while certain faults are present, but will operate with diminished performance with other faults present. The HS-CAN bus may remain operational when 1 of the 2 termination resistors are not present. The HS-CAN network operates at a maximum data transfer speed of 500 Kbps and is designed for real time information transfer and control. The network will remain operational, but at a degraded level, when certain circuit faults are present. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3030 The following modules are on the HS-CAN network: Instrument cluster - Powertrain control module (PCM) - Anti-lock brake system (ABS) module - Restraints control module (RCM) - Occupant classification sensor module - Transmission control module (TCM) (if equipped) - Four wheel drive (4WD) control module (if equipped) HS-CAN Network Communication Fault Chart The fault chart describes the specific HS-CAN network failures and their resulting symptom: Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3031 CAN Network Module Communication Message Chart (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3032 CAN Network Module Communication Message Chart (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3033 CAN Network Module Communication Message Chart (Part 3) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3034 CAN Network Module Communication Message Chart (Part 4) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3035 CAN Network Module Communication Message Chart (Part 5) The chart describes the specific CAN network messages broadcast by each module, and the module(s) that receive the message: Inspection and Verification INSPECTION AND VERIFICATION This provides step-by-step module configuration procedures. Carry out the programmable module installation (PMI) procedure when another directs to carry out configuration or when DTCs from the list are present. Principles of Operation PRINCIPLES OF OPERATION Configurable modules accommodate a variety of vehicle options, eliminating the need for many unique modules for one vehicle line. These modules must be configured when replaced as part of a repair procedure. Configurable modules should not be exchanged between vehicles since the settings are unique to each vehicle. Failure to configure a new module may result in improper operation and/or any of the following DTCs setting: - B2477 and/or B2141 - sets when a body/chassis module is not configured. - B2900 - sets when there is a VIN mismatch between the module with the B2900 and the PCM. Either the PCM or the body module stored VIN Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3036 may be incorrect. - P0602, P0605 and/or P1639 - sets when the powertrain control module (PCM) vehicle identification (VID) block is not configured or is configured incorrectly. - U0300 and/or U0301 - sets when the configuration between 2 or more modules do not match. - U2050 and/or U2051 - sets when a valid strategy/calibration is not present. The following are the 3 different methods of configuration: - Programmable module installation (PMI) - Module reprogramming ("flashing") - Programmable parameters Some modules do not support all 3 methods. Definition of Terms The following are definitions of configuration terms: Programmable Module Installation (PMI) PMI is a scan tool process which configures settings in a new module. Data used for the PMI process is automatically downloaded from the original module and stored when a scan tool session is started. If this data cannot be retrieved from the module being replaced, the scan tool may prompt for As-Built data entry or display a list of parameter values that need to be manually selected. Some modules are reprogrammed during PMI when a strategy/calibration update is available. NOTE: A module must be able to communicate with the scan tool in order to carry out PMI. It is important that the scan tool identifies the vehicle and obtains configuration data prior to removing any modules. To carry out PMI, refer to Programmable Module Installation. Module Reprogramming Module reprogramming (also referred to as "flashing") is a scan tool process which updates the strategy/calibration in a module. Module reprogramming is automatically carried out during PMI when a later strategy/calibration is available. Reprogramming a module with the same level of software will not improve module operation or repair a hardware failure. NOTE: Module reprogramming should be limited to circumstances where a published Technical Service Bulletin (TSB) procedure recommends doing so. - A module cannot communicate with other modules on the communication network while being reprogrammed. Clear any network communication DTCs which may have been set in other modules during reprogramming. Programmable Parameters Programmable parameters are customer preference items that may be modified by the dealer via scan tool or in some cases modified by the customer following a procedure listed in the vehicle Owner's Literature. While many configuration options may exist for a module, only a few of these options are programmable parameters. Adaptive Learning and Calibration Some modules require a separate learning procedure be carried out if replaced as part of a repair procedure. For adaptive learning and calibration instructions, refer to the specific module removal and installation procedures. Vehicle Identification (VID) Block Some PCMs contain a memory area called a vehicle identification (VID) block. The PCM VID block commonly stores powertrain configuration items such as VIN, tire size, axle ratio, and whether or not the vehicle is equipped with speed control. As-Built Data As-Built data is a VIN specific module configuration record. During vehicle build, the configuration from all modules is downloaded and stored in the As-Built database. As Built data will not reflect customer preference items that have been changed from the default state. These items will need to be changed using programmable parameters after the module is configured. NOTE: It is not necessary to obtain As-Built data unless directed to do so by the scan tool. This data may be accessed from the technician service publication website. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3037 Body/Chassis Module Addresses for As-Built Entry The chart lists body/chassis module As-Built data addresses. Module Configuration And Parameter Chart (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3038 Module Configuration And Parameter Chart (Part 2) The chart describes specific module programming information. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3039 Information Bus: Diagnostic Trouble Code Descriptions U0073-U0140 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3040 U0154-U1900 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3041 U1900-U2471 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3042 U2472-U2511 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3043 B2477-B2900 / P0602-P1639 / U0300-U2050 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3044 U2051 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3045 Information Bus: Symptom Related Diagnostic Procedures Symptom Chart (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3046 Symptom Chart (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3047 Information Bus: Pinpoint Tests Test A: The Powertrain Control Module (PCM) Does Not Respond to the Scan Tool PINPOINT TEST A: THE POWERTRAIN CONTROL MODULE (PCM) DOES NOT RESPOND TO THE SCAN TOOL A1-A2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3048 A3-A4 Normal Operation The PCM communicates with the scan tool through the high speed controller area network (HS-CAN). Circuits VDB04 (WH/BU) (HS-CAN +) and VDB05 (WH) (HS-CAN -) provide the network connection to the PCM. The PCM shares the HS-CAN network with the transmission control module (TCM) (if equipped), the anti-lock brake system (ABS) module, the restraints control module (RCM), the four wheel drive (4WD) control module (if equipped), the occupant classification sensor module and the instrument cluster. Possible Causes - Circuit VDB04 (WH/BU) open (HS-CAN +) - Circuit VDB05 (WH) open (HS-CAN -) - PCM Test B: The Transmission Control Module (TCM) Does Not Respond to the Scan Tool PINPOINT TEST B: THE TRANSMISSION CONTROL MODULE (TCM) DOES NOT RESPOND TO THE SCAN TOOL Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3049 B1-B2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3050 B3-B4 Normal Operation The 6R60 transmission utilizes a TCM to control transmission functions. The TCM communicates with the scan tool through the high speed controller area network (HS-CAN). Circuits VDB04 (WH/BU) (HS-CAN +) and VDB05 (WH) (HS-CAN -) provide the network connection to the TCM. The TCM shares the HS-CAN network with the powertrain control module (PCM), the anti-lock brake system (ABS) module, the restraints control module (RCM), the four wheel drive (4WD) control module (if equipped), the occupant classification sensor module and the instrument cluster. Voltage for the TCM is provided by circuits SBB27 (BU/RD) and CE517 (BU/GN). Circuit GD113 (BK/YE) provides ground. Possible Causes - Fuse - Circuit CE517 (BU/GN) open - Circuit GD113 (BK/YE) open - Circuit SBB27 (BU/RD) open - Circuit VDB04 (WH/BU) open (HS-CAN +) - Circuit VDB05 (WH) open (HS-CAN -) - TCM Test C: The Anti-Lock Brake System (ABS) Module Does Not Respond to the Scan Tool Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3051 PINPOINT TEST C: THE ANTI-LOCK BRAKE SYSTEM (ABS) MODULE DOES NOT RESPOND TO THE SCAN TOOL C1-C2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3052 C3-C4 Normal Operation The ABS module communicates with the scan tool through the high speed controller area network (HS-CAN). Circuits VDB04 (WH/BU) (HS-CAN +) and VDB05 (WH) (HS-CAN -) provide the network connection to the ABS module. The ABS module shares the HS-CAN network with the powertrain control module (PCM), the transmission control module (TCM) (if equipped), the restraints control module (RCM), the four wheel drive (4WD) control module (if equipped), the occupant classification sensor module and the instrument cluster. Voltage for the ABS module is provided by circuits CBP18 (GY/OG), SBB06 (BN/RD) and SBB33 (RD). Ground is provided by circuit GD120 (BK/GN). Possible Causes - Fuse - Circuit CBP18 (GY/OG) open - Circuit SBB06 (BN/RD) open - Circuit SBB33 (RD) open - Circuit GD120 (BK/GN) open - Circuit VDB04 (WH/BU) open (HS-CAN +) - Circuit VDB05 (WH) open (HS-CAN -) - ABS module Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3053 Test D: The Restraints Control Module (RCM) Does Not Respond to the Scan Tool PINPOINT TEST D: THE RESTRAINTS CONTROL MODULE (RCM) DOES NOT RESPOND TO THE SCAN TOOL D1-D2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3054 D2-D4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3055 D4-D5 Normal Operation The RCM communicates with the scan tool through the high speed controller area network (HS-CAN). Circuits VDB04 (WH/BU) (HS-CAN +) and VDB05 (WH) (HS-CAN -) provide the network connection to the RCM. The RCM shares the HS-CAN network with the powertrain control module (PCM), the transmission control module (TCM) (if equipped), the anti-lock brake system (ABS) module, the four wheel drive (4WD) control module (if equipped), the occupant classification sensor module and the instrument cluster. Voltage for the RCM is provided by circuit CBP17 (BN/GN), and the RCM is case grounded. Possible Causes - Fuse - Circuit CBP17 (BN/GN) open - Circuit VDB04 (WH/BU) open (HS-CAN +) - Circuit VDB05 (WH) open (HS-CAN -) - Case ground open - RCM Test E: The Four Wheel Drive (4WD) Control Module Does Not Respond to the Scan Tool PINPOINT TEST E: THE FOUR WHEEL DRIVE (4WD) CONTROL MODULE DOES NOT RESPOND TO THE SCAN TOOL Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3056 E1-E3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3057 E3-E4 Normal Operation The 4WD control module communicates with the scan tool through the high speed controller area network (HS-CAN). Circuits VDB04 (WH/BU) (HS-CAN +) and VDB05 (WH) (HS-CAN -) provide the network connection to the 4WD control module. The 4WD control module shares the HS-CAN with powertrain control module (PCM), the transmission control module (TCM) (if equipped), the anti-lock brake system (ABS) module, the restraints control module (RCM), the occupant classification sensor module and the instrument cluster. Voltage is supplied by circuits CBP18 (GY/OG), SBB23 (RD/WH) and SBB26 (RD/BK). Ground is supplied by circuits GD138 (BK/WH) and GD145 (BK/BU). Possible Causes - Fuse - Circuit CBP18 (GY/OG) open - Circuit GD138 (BK/WH) open - Circuit GD145 (BK/BU) open - Circuit SBB23 (RD/WH) open - Circuit SBB26 (RD/BK) open - Circuit VDB04 (WH/BU) open (HS-CAN +) - Circuit VDB05 (WH) open (HS-CAN -) - 4WD control module Test F: The Occupant Classification Sensor Module Does Not Respond to the Scan Tool PINPOINT TEST F: THE OCCUPANT CLASSIFICATION SENSOR MODULE DOES NOT RESPOND TO THE SCAN TOOL Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3058 F1-F2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3059 F2-F3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3060 F4 Normal Operation The occupant classification sensor module communicates with the scan tool through the high speed controller area network (HS-CAN). Circuits VDB04 (WH/BU) (HS-CAN +) and VDB05 (WH) (HS-CAN -) provide the network connection to the occupant classification sensor module. The occupant classification sensor module shares the HS-CAN with the powertrain control module (PCM), the transmission control module (TCM) (if equipped), the anti-lock brake system (ABS) module, the restraints control module (RCM), the four wheel drive (4WD) control module (if equipped) and the instrument cluster. Voltage to the occupant classification sensor module is supplied by circuit CBP17 (BN/GN). Ground is supplied by circuit GD145 (BK/BU). Possible Causes - Fuse - Circuit CBP17 (BN/GN) open - Circuit GD145 (BK/BU) open - Circuit VDB04 (WH/BU) open (HS-CAN +) - Circuit VDB05 (WH) open (HS-CAN -) - Occupant classification sensor module Test G: The Instrument Cluster Does Not Respond to the Scan Tool PINPOINT TEST G: THE INSTRUMENT CLUSTER DOES NOT RESPOND TO THE SCAN TOOL Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3061 G1-G3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3062 G3-G4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3063 G5 Normal Operation The instrument cluster communicates with the scan tool through the high speed controller area network (HS-CAN). Circuits VDB04 (WH/BU) (HS-CAN +) and VDB05 (WH) (HS-CAN -) provide the HS-CAN network connection to the instrument cluster and circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the MS-CAN network connection to the instrument cluster. The instrument cluster shares the HS-CAN network with the powertrain control module (PCM), the transmission control module (TCM) (if equipped), the anti-lock brake system (ABS) module, the restraint control module (RCM), the four wheel drive (4WD) control module (if equipped) and the occupant classification sensor module. The instrument cluster shares the MS-CAN network with the smart junction box (SJB), the electronic automatic temperature control (EATC) module (if equipped), the audio unit, the satellite radio receiver (if equipped), the driver seat module (DSM) (if equipped), the parking aid module (if equipped), the power running board module (if equipped) and the digital versatile disc (DVD) player (if equipped). Voltage for the instrument cluster is provided by circuits CDC34 (WH/OG) and SBP24 (VT/RD). Circuit GD145 (BK/BU) provides ground. Possible Causes - Fuse - Circuit CDC34 (WH/OG) open - Circuit GD145 (BK/BU) open - Circuit SBP24 (VT/RD) open - Circuit VDB04 (WH/BU) open (HS-CAN +) - Circuit VDB05 (WH) open (HS-CAN -) - Instrument cluster Test H: The Smart Junction Box (SJB) Does Not Respond to the Scan Tool PINPOINT TEST H: THE SMART JUNCTION BOX (SJB) DOES NOT RESPOND TO THE SCAN TOOL H1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3064 H1-H3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3065 H3-H4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3066 H5 Normal Operation The SJB communicates with the scan tool through the medium speed controller area network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the SJB. The SJB shares the MS-CAN network with the instrument cluster, the electronic automatic temperature control (EATC) module (if equipped), the audio unit, the satellite radio receiver (if equipped), the driver seat module (DSM) (if equipped), the parking aid module (if equipped), the power running board module (if equipped), and the digital versatile disc (DVD) player (if equipped). Voltage for the SJB is provided by circuit SBB03 (BU/RD). Circuit GD108 (BK/VT) provides ground. Possible Causes - Fuse - Circuit SBB03 (BU/RD) open - Circuit GD108 (BK/VT) open - Circuit VDB06 (GY/OG) open (MS-CAN +) - Circuit VDB07 (VT/OG) open (MS-CAN -) - SJB Test I: The Electronic Automatic Temperature Control (EATC) Module Does Not Respond to the Scan Tool PINPOINT TEST I: THE ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC) MODULE DOES NOT RESPOND TO THE SCAN TOOL. I1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3067 I1-I2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3068 I3-I4 Normal Operation The EATC module communicates with the scan tool through the medium speed controller area network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the EATC module. The EATC module shares the MS-CAN network with the instrument cluster, the smart junction box (SJB), the audio unit, the satellite radio receiver (if equipped), the digital versatile disc (DVD) player (if equipped), the driver seat module (DSM) (if equipped), the power running board module (if equipped) and the parking aid module (if equipped). Voltage for the EATC module is provided by circuits CBP20 (YE/VT) and SBP28 (GN/RD). Circuit GD145 (BK/BU) provides ground. Possible Causes - Fuse - Circuit CBP20 (YE/VT) open - Circuit GD145 (BK/BU) open - Circuit SBP28 (GN/RD) open - Circuit VDB06 (GY/OG) open (MS-CAN +) - Circuit VDB07 (VT/OG) open (MS-CAN -) - EATC module Test J: The Audio Unit Does Not Respond to the Scan Tool Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3069 PINPOINT TEST J: THE AUDIO UNIT DOES NOT RESPOND TO THE SCAN TOOL J1-J2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3070 J2-J3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3071 J4 Normal Operation Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the audio unit. The audio unit shares the MS-CAN network with the instrument cluster, the smart junction box (SJB), the electronic automatic temperature control (EATC) module (if equipped), the satellite radio receiver (if equipped), the digital versatile disc (DVD) player, the driver seat module (DSM) (if equipped), the power running board module (if equipped) and the parking aid module (if equipped). Voltage for the audio unit is provided by circuits CBP12 (GN/WH) and SBP03 (BU/RD). Circuit GD114 (BK/BU) provides ground. Possible Causes - Fuse - Circuit CBP12 (GN/WH) open - Circuit GD114 (BK/BU) open - Circuit SBP03 (BU/RD) open - Circuit VDB06 (GY/OG) open (MS-CAN +) - Circuit VDB07 (VT/OG) open (MS-CAN -) - Audio unit Test K: The Satellite Radio Receiver Does Not Respond to the Scan Tool PINPOINT TEST K: THE SATELLITE RADIO RECEIVER DOES NOT RESPOND TO THE SCAN TOOL K1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3072 K1-K3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3073 K3-K4 Normal Operation The satellite radio receiver communicates with the scan tool through the medium speed controller area network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the satellite radio receiver. The satellite radio receiver shares the MS-CAN network with the instrument cluster, the smart junction box (SJB), the electronic automatic temperature control (EATC) module (if equipped), the audio unit, the digital versatile disc (DVD) player (if equipped), the driver seat module (DSM) (if equipped), the power running board module (if equipped), and the parking aid module (if equipped). Voltage for the satellite radio receiver is provided by circuit SBB41 (RD). Circuit GD114 (BK/BU) provides ground. Possible Causes - Fuse - Circuit GD114 (BK/BU) open - Circuit SBB41 (RD) open - Circuit VDB06 (GY/OG) open (MS-CAN +) - Circuit VDB07 (VT/OG) open (MS-CAN -) - Satellite radio receiver Test L: The Digital Versatile Disc (DVD) Player Does Not Respond to the Scan Tool PINPOINT TEST L: THE DIGITAL VERSATILE DISC (DVD) PLAYER DOES NOT RESPOND TO THE SCAN TOOL Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3074 L1-L2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3075 L3-L4 Normal Operation The DVD player communicates with the scan tool through the medium speed controller area network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the DVD player. The DVD player is only on vehicles equipped with rear seat entertainment. The DVD player shares the MS-CAN network with the instrument cluster, the smart junction box (SJB), the electronic automatic temperature control (EATC) module (if equipped), the audio unit, the satellite radio receiver (if equipped), the driver seat module (DSM) (if equipped), the digital versatile disc (DVD) player (if equipped), the power running board module (if equipped), and the parking aid module (if equipped). Voltage for the DVD player is provided by circuit SBB41 (RD). Circuit GD114 (BK/BU) provides ground. Possible Causes - Fuse - Circuit GD114 (BK/BU) open - Circuit SBB41 (RD) open - Circuit VDB06 (GY/OG) open (MS-CAN +) - Circuit VDB07 (VT/OG) open (MS-CAN -) - DVD player Test M: The Driver Seat Module (DSM) Does Not Respond to the Scan Tool Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3076 PINPOINT TEST M: THE DRIVER SEAT MODULE (DSM) DOES NOT RESPOND TO THE SCAN TOOL M1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3077 M2-M3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3078 M4 Normal Operation The DSM communicates with the scan tool through the medium speed controller area network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the DSM. The DSM shares the MS-CAN network with the instrument cluster, the smart junction box (SJB), the electronic automatic temperature control (EATC) module (if equipped), the audio unit, the digital versatile disc (DVD) player (if equipped), the satellite radio receiver (if equipped), the power running board module (if equipped) and the parking aid module (if equipped). Voltage for the DSM is provided by circuit SBP01 (RD). Circuit GD143 (BK/OG) provides ground. Possible Causes - Fuse - Circuit GD143 (BK/OG) open - Circuit SBP01 (RD) open - Circuit VDB06 (GY/OG) open (MS-CAN +) - Circuit VDB07 (VT/OG) open (MS-CAN -) - DSM Test N: The Power Running Board Module Does Not Respond to the Scan Tool PINPOINT TEST N: THE POWER RUNNING BOARD MODULE DOES NOT RESPOND TO THE SCAN TOOL N1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3079 N1-N2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3080 N3-N4 Normal Operation The power running board module communicates with the scan tool through the medium speed controller area network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the power running board module. The power running board module shares the MS-CAN network with the instrument cluster, the smart junction box (SJB), the electronic automatic temperature control (EATC) module (if equipped), the audio unit, the digital versatile disc (DVD) player (if equipped), the driver seat module (DSM) (if equipped), the satellite radio receiver (if equipped), and the parking aid module (if equipped). Voltage for the power running board module is provided by circuit SBB19 (BU/RD). Circuit GD151 (BK/GN) provides ground. Possible Causes - Fuse - Circuit GD151 (BK/GN) open - Circuit SBB19 (BU/RD) open - Circuit VDB06 (GY/OG) open (MS-CAN +) - Circuit VDB07 (VT/OG) open (MS-CAN -) - Power running board module Test O: The Parking Aid Module Does Not Respond to the Scan Tool Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3081 PINPOINT TEST O: THE PARKING AID MODULE DOES NOT RESPOND TO THE SCAN TOOL O1-O3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3082 O3-O4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3083 O5-O6 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3084 O7-O8 Normal Operation The parking aid module communicates with the scan tool through the medium speed controller area network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the parking aid module. The parking aid module shares the MS-CAN network with the instrument cluster, the smart junction box (SJB), the electronic automatic temperature control (EATC) module (if equipped), the audio unit, the digital versatile disc (DVD) player (if equipped), the satellite radio receiver (if equipped), and the power running board module (if equipped). Voltage for the parking aid module is provided by circuit CBP18 (GY/OG). Circuit GD145 (BK/BU) provides ground. Possible Causes - Fuse - Circuit CBP18 (GY/OG) open - Circuit GD145 (BK/BU) open - Circuit VDB06 (GY/OG) open (MS-CAN +) - Circuit VDB07 (VT/OG) open (MS-CAN -) - Parking aid module Test P: No Medium Speed Controller Area Network (MS-CAN) Communication, All Modules Are Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3085 Not Responding PINPOINT TEST P: NO MEDIUM SPEED CONTROLLER AREA NETWORK (MS-CAN) COMMUNICATION, ALL MODULES ARE NOT RESPONDING P1-P2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3086 P2-P4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3087 P5-P7 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3088 P7-P8 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3089 P9-P12 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3090 P12-P16 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3091 P16-P20 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3092 P20-P23 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3093 P23-P25 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3094 P25-P29 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3095 P29-P33 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3096 P33-P36 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3097 P37-P40 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3098 P41-P45 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3099 P46 Normal Operation The MS-CAN network uses an unshielded twisted pair cable, circuits VDB06 (GY/OG) and VDB07 (VT/OG) provide the network connection to all modules on the network. The smart junction box (SJB), the instrument cluster, the electronic automatic temperature control (EATC) module (if equipped), the audio unit, the satellite radio receiver (if equipped), the digital versatile disc (DVD) (if equipped), the power running board module (if equipped), the parking aid module (if equipped), and the driver seat module all communicate with the scan tool using the MS-CAN network. Possible Causes - Circuit VDB06 (GY/OG) open, short to ground or voltage (MS-CAN +) - Circuit VDB07 (VT/OG) open, short to ground or voltage (MS-CAN -) - Circuit VDB06 (GY/OG) (MS-CAN +) and circuit VDB07 (VT/OG) (MS-CAN -) shorted together - SJB - Instrument cluster - Audio unit - EATC module (if equipped) - DVD player (if equipped) - Driver seat module (DSM) (if equipped) - Satellite radio receiver (if equipped) - Power running board module (if equipped) - Parking aid module (if equipped) Test Q: No High Speed Controller Area Network (HS-CAN) Communication, All Modules Are Not Responding PINPOINT TEST Q: NO HIGH SPEED CONTROLLER AREA NETWORK (HS-CAN) COMMUNICATION, ALL MODULES ARE NOT RESPONDING Q1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3100 Q1-Q2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3101 Q3-Q4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3102 Q5-Q6 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3103 Q7-Q8 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3104 Q8-Q9 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3105 Q10-Q11 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3106 Q12-Q16 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3107 Q16-Q18 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3108 Q18-Q20 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3109 Q20-Q23 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3110 Q23-Q26 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3111 Q26-Q28 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3112 Q28-Q30 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3113 Q31-Q34 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3114 Q35 Normal Operation The HS-CAN uses an unshielded twisted pair cable, circuits VDB04 (WH/BU) and VDB05 (WH). The powertrain control module (PCM), the transmission control module (TCM), the anti-lock brake system (ABS) module, the restraints control module (RCM), the four wheel drive (4WD) control module (if equipped), the occupant classification sensor module and the instrument cluster all communicate with the scan tool using the HS-CAN. Possible Causes - Circuit VDB04 (WH/BU) open, short to ground or voltage (HS-CAN +) - Circuit VDB05 (WH) open, short to ground or voltage (HS-CAN -) - Circuit VDB04 (WH/BU) (HS-CAN +) and circuit VDB05 (WH) (HS-CAN -) shorted together - PCM - RCM - ABS module - Instrument cluster - TCM (if equipped) - 4WD control module (if equipped) - Occupant classification sensor module Test R: No Power to the Scan Tool PINPOINT TEST R: NO POWER TO THE SCAN TOOL R1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3115 R2-R3 Normal Operation The scan tool is connected to the data link connector (DLC) to communicate with the high speed controller area network (HS-CAN) and the medium speed controller area network (MS-CAN) communications network. Voltage for the scan tool is provided by circuit SBP04 (GN/RD). Ground is provided by circuits GD108 (BK/VT) and GD138 (BK/WH). Possible Causes - Fuse - Circuit SBP04 (GN/RD) open - Circuit GD108 (BK/VT) open - Circuit GD138 (BK/WH) open - Scan tool Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3116 Information Bus: Programming and Relearning PROGRAMMABLE MODULE INSTALLATION Special Tool(s) Special Tool(s) Programmable Module Installation (PMI) Using The Integrated Diagnostic System (IDS) When The Original Module Is Available NOTE: Following module installation, some modules require a separate learning procedure be carried out. For instructions, refer to the specific module removal and installation procedures. 1. Connect the IDS and identify the vehicle as normal. 2. From the Toolbox icon, select Module Programming and press the check mark. 3. Select Programmable Module Installation. 4. Select the module that is being replaced. 5. Follow the on-screen instructions, turn the ignition key to the OFF position, and press the check mark. 6. Install the new module and press the check mark. 7. Follow the on-screen instructions, turn the ignition key to the ON position, and press the check mark. 8. The IDS downloads the data into the new module and displays Module Configuration Complete. 9. Test module for correct operation. Programmable Module Installation (PMI) Using The Integrated Diagnostic System (IDS) When The Original Module Is Not Available NOTE: Following module installation, some modules require a separate learning procedure be carried out. For adaptive learning and calibration instructions, refer to the specific module removal and installation procedures. 1. Install the new module. 2. Connect the IDS and identify the vehicle as normal. 3. From the Toolbox icon, select Module Programming and press the check mark. 4. Select Programmable Module Installation. 5. Select the module that was replaced. 6. Follow the on-screen instructions, turn the ignition key to the OFF position, and press the check mark. 7. Follow the on-screen instructions, turn the ignition key to the ON position, and press the check mark. 8. If the data is not available, the IDS displays a screen stating to contact the As-Built Data Center. Retrieve the data from the technician service publication website at this time and press the check mark. 9. Enter the module data and press the check mark. 10. The IDS downloads the data into the new module and displays Module Configuration Complete. 11. Test module for correct operation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Page 3117 Information Bus: Service and Repair PROGRAMMABLE MODULE INSTALLATION Special Tool(s) Special Tool(s) Programmable Module Installation (PMI) Using The Integrated Diagnostic System (IDS) When The Original Module Is Available NOTE: Following module installation, some modules require a separate learning procedure be carried out. For instructions, refer to the specific module removal and installation procedures. 1. Connect the IDS and identify the vehicle as normal. 2. From the Toolbox icon, select Module Programming and press the check mark. 3. Select Programmable Module Installation. 4. Select the module that is being replaced. 5. Follow the on-screen instructions, turn the ignition key to the OFF position, and press the check mark. 6. Install the new module and press the check mark. 7. Follow the on-screen instructions, turn the ignition key to the ON position, and press the check mark. 8. The IDS downloads the data into the new module and displays Module Configuration Complete. 9. Test module for correct operation. Programmable Module Installation (PMI) Using The Integrated Diagnostic System (IDS) When The Original Module Is Not Available NOTE: Following module installation, some modules require a separate learning procedure be carried out. For adaptive learning and calibration instructions, refer to the specific module removal and installation procedures. 1. Install the new module. 2. Connect the IDS and identify the vehicle as normal. 3. From the Toolbox icon, select Module Programming and press the check mark. 4. Select Programmable Module Installation. 5. Select the module that was replaced. 6. Follow the on-screen instructions, turn the ignition key to the OFF position, and press the check mark. 7. Follow the on-screen instructions, turn the ignition key to the ON position, and press the check mark. 8. If the data is not available, the IDS displays a screen stating to contact the As-Built Data Center. Retrieve the data from the technician service publication website at this time and press the check mark. 9. Enter the module data and press the check mark. 10. The IDS downloads the data into the new module and displays Module Configuration Complete. 11. Test module for correct operation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Tools and Equipment > Module Communications Network Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Tools and Equipment > Module Communications Network > Page 3120 Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3124 C108 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3125 Knock Sensor: Description and Operation KNOCK SENSOR (KS) Two Types Of Knock Sensor (KS) The KS 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3126 Knock Sensor: Service and Repair KNOCK SENSOR (KS) Removal and Installation 1. Remove the intake manifold. 2. Disconnect the knock sensor (KS) electrical connector. 3. Remove the bolt and the KS. - To install, tighten to 20 Nm (15 lb-ft). 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3130 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) CHECK ENGINE, SERVICE ENGINE SOON, Or ISO Standard Engine Symbol The MIL notifies the driver that the powertrain control module (PCM) has detected an on board diagnostic (OBD) emission-related component or system concern. When this occurs, an OBD diagnostic trouble code (DTC) sets. - The MIL is located in the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE SOON or the international standards organization (ISO) standard engine symbol. - The MIL is illuminated during the instrument cluster prove out for approximately 4 seconds. - The MIL remains illuminated after instrument cluster prove out if: an emission-related concern and DTC exists. - the PCM does not send a control message to the instrument cluster (applications with the MIL controlled through the communication link). - the PCM is operating in the hardware limited operation strategy (HLOS). - The MIL remains off during the instrument cluster prove out if an indicator or instrument cluster concern is present. - To turn off the MIL after a repair, a reset command from the scan tool must be sent, or 3 consecutive drive cycles must be completed without a concern. - For all MIL concerns, go to Symptom Charts. See: Testing and Inspection/Symptom Related Diagnostic Procedures - If the MIL flashes at a steady rate, a severe misfire condition may exist. - If the MIL flashes erratically, the PCM can reset while cranking if the battery voltage is low. - The MIL flashes after a period of time with the key in the RUN position (engine not running) if DTC P1000 is set. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation Manifold Pressure/Vacuum Sensor: Description and Operation MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR Typical Manifold Absolute Pressure (MAP) Sensor The MAP sensor measures intake manifold absolute pressure. The PCM uses information from the MAP sensor to measure how much exhaust gas is introduced into the intake manifold. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Diagrams C104 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Diagrams > Page 3140 Oil Temperature Sensor For ECM: Description and Operation ENGINE OIL TEMPERATURE (EOT) SENSOR Typical EOT Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance changes 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 EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system. The PCM can use the EOT sensor input to determine the following: - On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM begins reducing power by disabling engine cylinders. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Diagrams > Page 3141 Oil Temperature Sensor For ECM: Service and Repair OIL TEMPERATURE SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine oil. - Install the drain plug and tighten to 26 Nm (19 lb-ft). 3. Disconnect the oil temperature sensor electrical connector. 4. Remove the oil temperature sensor. - To install, tighten to 15 Nm (11 lb-ft). 5. To install, reverse the removal procedure. - Inspect the O-ring seal and install a new O-ring seal if necessary. - Fill the engine with clean engine oil. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3146 View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3147 View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3148 View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 C141 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 3151 C142 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 3152 C171 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 3153 C172 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3154 Oxygen Sensor: Description and Operation HEATED OXYGEN SENSOR (HO2S) Heated Oxygen Sensor (HO2S) The HO2S 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 voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a 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 a temperature of 800°C (1,472°F). At approximately 300°C (572°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater. The PCM turns the heater on by providing the ground when the correct conditions occur. The heater allows the engine to enter closed loop operation sooner. The use of this heater requires the HO2S heater control to be duty cycled, to prevent damage to the heater. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) HEATED OXYGEN SENSOR (HO2S) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3157 Exploded View Special Tool(s) Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If the RH heated oxygen sensor (HO2S) is being serviced, remove the bolts and position the heat shield aside. - To install, tighten to 20 Nm (15 lb-ft). 3. Disconnect the HO2S electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3158 4. NOTE: If necessary, lubricate the HO2S with penetrating and lock lubricant to ease removal. Using the special tool, remove the HO2S. To install, tighten to 41 Nm (30 lb-ft). 5. To install, reverse the removal procedure. - Apply a light coat of nickel anti-seize lubricant to the threads of the HO2S. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3159 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor CATALYST MONITOR SENSOR Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3160 Exploded View Special Tool(s) Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the catalyst monitor sensor electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3161 3. NOTE: If necessary, lubricate the catalyst monitor sensor with penetrating and lock lubricant to ease removal. Using the special tool, remove the catalyst monitor sensor. To install, tighten to 41 Nm (30 lb-ft). 4. To install, reverse the removal procedure. - Apply a light coat of anti-seize lubricant to the threads of the catalyst monitor sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations View 151-2 (Engine Compartment - 4.0L, (2 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 3165 C121 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch POWER STEERING PRESSURE (PSP) SWITCH Typical Power Steering Pressure (PSP) Switch The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch > Page 3168 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor POWER STEERING PRESSURE (PSP) SENSOR Typical Power Steering Pressure (PSP) Sensor The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM changes as the hydraulic pressure changes. The PCM uses the input signal from the PSP sensor to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP sensor signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example, during parking maneuvers. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor The differential pressure feedback EGR sensor 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 EGR sensor receives this signal through 2 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 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. DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR TUBE MOUNTED Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 3172 The tube mounted differential pressure feedback EGR sensor is identical in operation as the large plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 3173 Pressure Feedback Exhaust Sensor: Service and Repair EXHAUST GAS RECIRCULATION (EGR) SYSTEM MODULE Exploded View Removal and Installation 1. Disconnect the exhaust gas recirculation (EGR) system module electrical and vacuum connectors. 2. Disconnect the EGR system module-to-exhaust manifold tube upper fitting. - To install, tighten to 40 Nm (30 lb-ft). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 3174 3. NOTE: When installing the new EGR module gasket, install with the side with the raised circle facing the intake manifold. Remove the bolts, the EGR system module and the gasket. Discard the gasket. To install, tighten to 25 Nm (18 lb-ft). 4. NOTE: The EGR system module sealing surfaces are soft metals. Carefully clean the EGR system module sealing surfaces. 5. To install, reverse the removal procedure. - Install a new EGR system module gasket. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Specifications Torque Specifications Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) Body Control Module: Service and Repair Driver Seat Module (DSM) DRIVER SEAT MODULE (DSM) Special Tool(s) Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 3181 Removal and Installation CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: Prior to the removal of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new DSM after installation. 1. Remove the driver seat. 2. Remove the 2 DSM screws. 3. Disconnect the electrical connectors and remove the DSM. 4. NOTE: Once the module is installed it is necessary to download the module configuration information from the scan tool into the new module. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 3182 Body Control Module: Service and Repair Smart Junction Box (Sjb) SMART JUNCTION BOX (SJB) Special Tool(s) Special Tool(s) Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 3183 Part 2 Removal NOTE: - The steps included in the SJB removal and installation procedure are critical to restoring the vehicle security and tire pressure monitoring systems to normal operation. A new SJB is delivered in manufacturing mode with 6 pre-set diagnostic trouble codes (DTCs) related to the tire pressure monitoring system. The presence of these DTCs requires the installation procedures be followed in order to clear the DTCs and enable normal SJB operations. - Prior to the removal of the SJB, it is necessary to upload the module configuration information to the diagnostic tool. This information must be downloaded to the new SJB after installation. 1. Remove the driver door scuff plate. 2. Position the LH door opening weather seal aside. 3. NOTE: While pulling the trim panel rearward, pull the hood release lever rearward in order for the release lever to slide through the trim panel. Remove the pushpin and the cowl side trim panel. 4. Remove the 2 bolts and the parking brake release handle. 5. Disconnect the parking brake switch electrical connector. 6. Release the hood release cable pushpin from the parking brake control bracket. 7. Release the harness clip from the parking brake cable housing. 8. NOTE: Rotating the parking brake control counterclockwise allows enough access to clear the instrument panel reinforcement. Remove the 3 bolts and position the parking brake control assembly under the brake pedal. 9. CAUTION: The lower side of the headlight switch bezel includes 2 tabs that slide down onto the instrument panel and may be broken if any prying force is exerted in the lower area of the bezel. Using a suitable tool, pry the mid-to-upper side of the headlight switch bezel away from the instrument panel, disconnect the 2 electrical connectors and position the bezel assembly aside. 10. If necessary, push the LH instrument panel side finish panel out and position it aside. 11. Through the headlight switch bezel opening, remove the 2 SJB bolts. 12. From under the instrument panel, remove the third SJB bolt. 13. NOTE: The SJB electrical connector levers must click into a fully released position before they can be removed and must click into a fully closed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 3184 (connected) position when installing. Pull the SJB down out of the 2 locating pins, disconnect the 5 electrical connectors and remove the SJB. Installation NOTE: When a new SJB is installed, all customer RKE transmitters may be required to program the RKE transmitters to the new SJB. 1. NOTE: The SJB electrical connector levers must click into a fully released position before they can be removed and must click into a fully closed (connected) position when installing. Position the SJB into the 2 locating pins and connect the 5 electrical connectors. 2. From under the instrument panel, install the SJB bolt. 3. Through the headlight switch bezel opening, install the 2 SJB bolts. 4. If necessary, install the LH instrument panel side finish panel. 5. Connect the 2 electrical connectors and install the headlight switch bezel assembly into the instrument panel. 6. Position the parking brake control assembly and install the 3 bolts. - Tighten to 20 Nm (15 lb-ft). 7. Install the harness clip on the parking brake cable housing. 8. Install the hood release cable pushpin into the parking brake control bracket. 9. Connect the parking brake switch electrical connector. 10. Position the parking brake release handle and install the 2 bolts. 11. Position the hood release lever assembly and install the bolt. 12. NOTE: While installing the trim panel, pull the hood release lever rearward in order for the release lever to slide through the trim panel. Position the cowl side trim panel and install the pushpin. 13. Position the LH door opening weather seal. 14. Install the driver door scuff plate. 15. NOTE: When successful, this step provides the calibration necessary for SJB operation and clears DTC B2477. The clearing of the DTC indicates the calibration data has been successfully downloaded to the SJB. Download the SJB configuration information from the diagnostic tool to the SJB. 16. NOTE: When successful, this step clears DTCs B2868, B2869, B2870 and B2871. The clearing of these DTCs indicates the SJB has recognized the tire pressure sensors during the training procedure. Train the tire pressure sensors. 17. Clear the DTCs. 18. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode, and to be sure there are no other concerns with the newly programmed SJB. Carry out the SJB on-demand self-test. 19. NOTE: If the module configuration upload/download is successful, then the RKE transmitters do not need to be reprogrammed to the vehicle. However, if the module configuration upload/download is unsuccessful and as-built data must be used to configure the module, then ALL of the customer's RKE transmitters must be reprogrammed to the vehicle. Program the RKE transmitters to the new SJB (if necessary). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation Electronic Throttle Control Module: Description and Operation TORQUE BASED ELECTRONIC THROTTLE CONTROL (ETC) Overview The torque based ETC is a hardware and software strategy that delivers an engine output torque (via throttle angle) based on driver demand (pedal position). It uses an electronic throttle body, the powertrain control module (PCM), and an accelerator pedal assembly to control the throttle opening and engine torque. The ETC system replaces the standard cable operated accelerator pedal, idle air control (IAC) valve, 3-wire throttle position (TP) sensor, and mechanical throttle body. Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque during shifts, and by calculating this desired torque, the system prevents engine lugging (low RPM and low manifold vacuum) while still delivering the performance and torque requested by the driver. It also enables many fuel economy/emission improvement technologies such as variable camshaft timing (VCT) (deliver same torque during transitions). Torque based ETC also results in less intrusive vehicle and engine speed limiting, along with smoother traction control. Other benefits of ETC are: eliminate cruise control actuators - eliminate idle air control (IAC) valve - better airflow range - packaging (no cable) - more responsive powertrain at altitude and improved shift quality It should be noted that the ETC system illuminates a powertrain malfunction indicator (wrench) on the instrument cluster when a concern is present. Concerns are accompanied by diagnostic trouble codes (DTCs) and may also illuminate the malfunction indicator lamp (MIL). Electronic Throttle Body (ETB) The ETB has the following characteristics: 1. The throttle actuator control (TAC) motor is a DC motor controlled by the PCM (requires 2-wires). The gear ratio from the motor to the throttle plate shaft is 17:1. 2. There are 2 designs: parallel and in-series. The parallel design has the motor under the bore parallel to the plate shaft. The motor housing is integrated into the main housing. The in-series design has a separate motor housing. 3. Two springs are used: one is used to close the throttle (main spring) and the other is in a plunger assembly that results in a default angle when no power is applied. This is for limp home reasons (the force of the plunger spring is 2 times stronger than the main spring). The default angle is usually set to result in a top vehicle speed of 48 km/h (30 mph). Typically this throttle angle is 7 to 8 degrees from the hard-stop angle. 4. The closed throttle plate hard stop is used to prevent the throttle from binding in the bore (~0.75 degree). This hard stop setting is not adjustable and is set to result in less airflow than the minimum engine airflow required at idle. 5. Unlike cable operated throttle bodies, the intent for the ETB is not to have a hole in the throttle plate or to use plate sealant. The hole is not required in the ETB because the required idle airflow is provided by the plate angle in the throttle body assembly. This plate angle controls idle, idle quality, and eliminates the need for an IAC valve. 6. The TP sensor has 2 signal circuits in the sensor for redundancy. The redundant throttle position signals are required for increased monitoring reasons. The first TP signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). During normal operation the negative slope TP signal (TP1) is used by the control strategy as the indication of throttle position. The TP sensor assembly requires 4 circuits. 5-volt reference voltage - Signal return (ground) - TP1 voltage with negative voltage slope (5-0 volts) - TP2 voltage with positive voltage slope (0-5 volts) Accelerator Pedal Position (APP) Sensors Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 3188 Electronic Throttle Body (ETB) And Accelerator Pedal Assembly The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1. There are 3 pedal position signals required for system monitoring. APP1 has a negative slope (increasing angle, decreasing voltage) and APP2 and APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. 2. There are 2 VREF circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. 2 reference voltage circuits (5 volts) - 2 signal return (ground) circuits - APP1 voltage with negative voltage slope (5-0 volts) - APP2 voltage with positive voltage slope (0-5 volts) - APP3 voltage with positive voltage slope (0-5 volts) 3. The pedal position signal is convened to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. 4. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. A value is substituted for an incorrect signal if 2 of the 3 signals are incorrect. Electronic Throttle Control (ETC) System Strategy Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 3189 ETC System The torque based ETC strategy was developed to improve fuel economy and to accommodate variable camshaft timing (VCT). This is possible by not coupling the throttle angle to the driver pedal position. Uncoupling the throttle angle (produce engine torque) from the pedal position (driver demand) allows the powertrain control strategy to optimize fuel control and transmission shift schedules while delivering the requested wheel torque. The ETC monitor system is distributed across 2 processors within the PCM: the main powertrain control processor unit (CPU) and a monitoring processor called an enhanced-quizzer (E-Quizzer) processor. The primary monitoring function is carried out by the independent plausibility check (IPC) software, which resides on the main processor. It is responsible for determining the driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the generated torque exceeds driver demand by a specified amount, the IPC takes appropriate corrective action. ETC System Failure Mode And Effects Management (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 3190 ETC System Failure Mode And Effects Management (Part 2) Since the IPC and the main controller share the same processor, they are subject to a number of potential common failure modes. The E-Quizzer processor was added to redundantly monitor selected PCM inputs and to act as an intelligent watchdog and monitor the performance of the IPC and the main processor. If it determines that the IPC function is impaired in any way, it takes appropriate failure mode and effects management (FMEM) actions. Electronic Throttle Monitor Operation: Electronic Throttle Monitor Operation (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 3191 Electronic Throttle Monitor Operation (Part 2) Accelerator and Throttle Position (TP) Sensor Inputs Accelerator Pedal Position (APP) Sensor Check: Accelerator Pedal Position (APP) Sensor Check Throttle Position (TP) Sensor Check: Throttle Position (TP) Sensor Check Throttle Plate Position Controller (TPPC) Outputs Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 3192 Throttle Plate Controller Check Operation The purpose of the TPPC is to maintain the throttle position at the desired throttle angle. It is a separate chip embedded in the PCM. The desired angle is communicated from the main CPU via a 312.5 Hz duty cycle (DC) signal. The TPPC interprets the duty cycle signal as follows: Less than 4% - Out of range, limp home default position. - Greater than or equal to 4% but less than 6% - Commanded default position, closed. - Greater than or equal to 6% but less than 7% - Commanded default position. Used for key ON, engine OFF. - Greater than or equal to 7% but less than 8% - Enable ice breaker mode. Used to clear potential ice buildup in the throttle body. - Greater than or equal to 8% but less than 10% - Closed against hard-stop. Used to learn zero throttle angle position (hard stop) after key-up. - Greater than or equal to 10% but less than or equal to 92% - Normal operation, between 0 degrees (hard stop) and 82 degrees, 10% duty cycle equals 0 degrees throttle angle, 92% duty cycle equals 82 degrees throttle angle. - Greater than 92% but less than or equal to 96% - Wide open throttle, 82 to 86 degrees throttle angle. - Greater than 96% but less than or equal to 100% - Out of range, limp home default position. The desired angle is relative to the hard-stop angle. The hard stop angle is learned during each key-up process before the main CPU requests the throttle plate be closed against the hard stop. The output of the TPPC is a voltage request to the H driver (also in PCM). The H driver is capable of positive or negative voltage to the electronic throttle body motor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start Engine Control Module: Customer Interest Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start TSB 08-18-2 09/15/08 MIL ON - P0506 AND/OR P0505 - HESITATION/LOSS OF RPM/DIFFICULTY STARTING/LOW IDLE RPM FORD: 2005-2007 Crown Victoria 2006 Mustang, Mustang 2004-2006 F-150, F-150 2005-2006 E-350, E-450, F-Super Duty 2006 F-53 Motorhome Chassis 2006-2007 Explorer Sport Trac, Explorer LINCOLN: 2005-2007 Town Car 2006 Mark LT MERCURY: 2005-2007 Grand Marquis 2006-2007 Mountaineer, Mountaineer This article supersedes TSB(s) 08-5-13, 07-23-12 and 06-25-8 to update the Service Procedure. ISSUE Some 2004-2006 4.6L and 5.4L F-150 (excluding F-150 Heritage), 2006 5.4L Mark LT, 2005-2006 6.8L E-350 / E-450, 2005-2006 6.8L F-Super Duty (F-250 to F-550), 2006 6.8L F-53 Motorhome Chassis, 2006-2007 4.0L Explorer 4 dr, 2007 4.0L Explorer Sport Trac, 2006-2007 4.0L Mountaineer, 2006 4.0L Mustang, 2006 - 2007 4.6L 3V Explorer / Explorer Sport Trac / Mountaineer, 2006 4.6L 3V Mustang, and 2005-2007 Crown Vic / Grand Marquis / Towncar vehicles may exhibit one or more of the following symptoms: drive-away hesitation, loss of RPM on deceleration, difficulty starting, and/or idle RPM less than desired. Malfunction indicator lamp (MIL) may be illuminated with diagnostic trouble codes (DTCs) P0506 and/or P0505. These conditions may appear after battery disconnect, dead battery condition, or keep alive memory (KAM) reset. The symptoms may be due to engine deposits in the throttle leading to air[low less than desired. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 53.9 and higher or 54.1 and higher. This new calibration is not included in the VCM 2008.1 DVD. Calibration files may also be obtained at the website. The calibration contains a sludge compensation strategy for the throttle body. 2. Turn the key off to re-initialize the PCM. This will allow the sludge compensation strategy to learn. 3. With the vehicle in park or neutral and A/C off, start vehicle and allow engine to reach normal operating temperature(greater than 170 °F (77 °C) coolant temperature). Run an additional 5 minutes to allow sufficient learning time. 4. While the engine is running, using IDS datalogger or equivalent, check the PID value of ETC_TRIM. a. If ETC_TRIM value is 3.5 degrees, and/or DTC PuSE is present, then replace the electronic throttle body (ETB), following Workshop Manual (WSM), Section 303-04B. b. If ETC_TRIM value is less than 3.5 degrees and DTC PuSE is not present, but driveability concerns persist, the ETB is not the likely cause of the concern and replacement is not necessary. Continue with normal PC/ED diagnostics. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start > Page 3201 NOTE VEHICLES EQUIPPED WITH A PCM AND TCM REQUIRE COORDINATED REPROGRAMMING. THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS OUTLINED BY THE IDS. FAILURE TO FOLLOW THE KEY CYCLE PROCEDURE WITHOUT WAITING FOR THE IDS PROMPTS, WILL CAUSE THE COORDINATED REPROGRAMMING TO FAIL. THE PCM WILL BE UPDATED BUT THE 1CM WILL NOT BE UPDATED AND NEW FILES WILL NOT BE INSTALLED. IT IS CRITICAL TO FOLLOW THE IDS PROMPTS. SOME VEHICLES MAY REQUIRE SEVERAL DAYS OF DRIVING FOR THE TRANSMISSION TO FULLY ADAPT. REPROGRAMMING CONCERNS/ERRORS MAY BE CAUSED BY THE DATA LINK CONNECTOR (DLC) OR VEHICLE COMMUNICATION MODULE (VCM) BECOMING DISCONNECTED, LOW BATTERIES ON THE INTEGRATED DIAGNOSTIC SYSTEM (IDS) OR THE IDS GOING INTO ANY TYPE OF SLEEP MODE, OR LOW VEHICLE BATTERY VOLTAGE. IF THERE WAS AN INTERRUPTION DURING REPROGRAMMING, MAKE SURE THE ORIGINAL IDS SESSION THAT WAS CREATED FOR THE VEHICLE IS NOT DELETED. IF THE ORIGINAL VEHICLE SESSION IS NOT USED OR DELETED BEFORE THE MODULES ARE COMPLETELY REPROGRAMMED, FURTHER REPROGRAMMING ERRORS CAN OCCUR. THE MODULE RECOVERY PROCEDURE IS NO LONGER AVAILABLE AND IT IS CRITICAL THAT MODULE SWAPPING IS NOT PERFORMED FROM VEHICLE TO VEHICLE. TO REGAIN COMMUNICATION WITH A MODULE THAT HAS BEEN ERASED DURING REPROGRAMMING, RESUME THE ORIGINAL SESSION ONCE THE IDS IS RE-BOOTED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081802A 2004-2006 F-150 0.4 Hr. 4.6L/5.4L, 2006 Mark LT, Econoline 350/450 6.8L 2005-2006 F-Super Duty 6.8L, 2006-2007 Explorer/Mountaineer 4.0L, 2007 Explorer Sport Trac 4.0L, 2006 Mustang 4.OL, 2005-2007 Crown Victoria, Town Car, Grand Marquis: Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Authorization Decal NOT Necessary. (Do Not Use With 9926A, 12650D) 081802A 2006-2007 1.0 Hr. Explorer/Mountaineer 4.6L, 2007 Explorer Sport Trac 4.6L: Check For DICs And Reprogram The PCM And 1CM, Includes Time To Monitor ETC_Trim Value, Authorization Decal NOT Necessary. (Do Not Use With 9926A, 12650D) 081802B 2004-2006 F-150 5.4L, 0.9 Hr. 2006 Mark LT: Check For DTCs And Reprogram The PCM, Includes Time To Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start > Page 3202 Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2004-2006 F-150 4.6L: 0.8 Hr. Check For DTCs And Reprogram The PCM Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2005-2006 Econoline 6.8L: 1.1 Hrs. Check For DTCs And Reprogram The PCM Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2005-2006 F-Super Duty 0.9 Hr. 6.8L: Check For DTCs And Reprogram The PCM Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2006-2007 Explorer, 1.4 Hrs. Mountaineer 2007 Explorer Sport Trac 4.6L: Check For DTCs And Reprogram The PCM And TCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2006-2007 Explorer, 0.8 Hr. Mountaineer 2007 Explorer Sport Trac 4.0L: Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2005-2007 Crown Victoria, 0.8 Hr. Town Car, Grand Marquis: Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start > Page 3203 Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2006 Mustang 4.0L/4.6L: 0.8 Hr. Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start TSB 08-18-2 09/15/08 MIL ON - P0506 AND/OR P0505 - HESITATION/LOSS OF RPM/DIFFICULTY STARTING/LOW IDLE RPM FORD: 2005-2007 Crown Victoria 2006 Mustang, Mustang 2004-2006 F-150, F-150 2005-2006 E-350, E-450, F-Super Duty 2006 F-53 Motorhome Chassis 2006-2007 Explorer Sport Trac, Explorer LINCOLN: 2005-2007 Town Car 2006 Mark LT MERCURY: 2005-2007 Grand Marquis 2006-2007 Mountaineer, Mountaineer This article supersedes TSB(s) 08-5-13, 07-23-12 and 06-25-8 to update the Service Procedure. ISSUE Some 2004-2006 4.6L and 5.4L F-150 (excluding F-150 Heritage), 2006 5.4L Mark LT, 2005-2006 6.8L E-350 / E-450, 2005-2006 6.8L F-Super Duty (F-250 to F-550), 2006 6.8L F-53 Motorhome Chassis, 2006-2007 4.0L Explorer 4 dr, 2007 4.0L Explorer Sport Trac, 2006-2007 4.0L Mountaineer, 2006 4.0L Mustang, 2006 - 2007 4.6L 3V Explorer / Explorer Sport Trac / Mountaineer, 2006 4.6L 3V Mustang, and 2005-2007 Crown Vic / Grand Marquis / Towncar vehicles may exhibit one or more of the following symptoms: drive-away hesitation, loss of RPM on deceleration, difficulty starting, and/or idle RPM less than desired. Malfunction indicator lamp (MIL) may be illuminated with diagnostic trouble codes (DTCs) P0506 and/or P0505. These conditions may appear after battery disconnect, dead battery condition, or keep alive memory (KAM) reset. The symptoms may be due to engine deposits in the throttle leading to air[low less than desired. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 53.9 and higher or 54.1 and higher. This new calibration is not included in the VCM 2008.1 DVD. Calibration files may also be obtained at the website. The calibration contains a sludge compensation strategy for the throttle body. 2. Turn the key off to re-initialize the PCM. This will allow the sludge compensation strategy to learn. 3. With the vehicle in park or neutral and A/C off, start vehicle and allow engine to reach normal operating temperature(greater than 170 °F (77 °C) coolant temperature). Run an additional 5 minutes to allow sufficient learning time. 4. While the engine is running, using IDS datalogger or equivalent, check the PID value of ETC_TRIM. a. If ETC_TRIM value is 3.5 degrees, and/or DTC PuSE is present, then replace the electronic throttle body (ETB), following Workshop Manual (WSM), Section 303-04B. b. If ETC_TRIM value is less than 3.5 degrees and DTC PuSE is not present, but driveability concerns persist, the ETB is not the likely cause of the concern and replacement is not necessary. Continue with normal PC/ED diagnostics. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start > Page 3209 NOTE VEHICLES EQUIPPED WITH A PCM AND TCM REQUIRE COORDINATED REPROGRAMMING. THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS OUTLINED BY THE IDS. FAILURE TO FOLLOW THE KEY CYCLE PROCEDURE WITHOUT WAITING FOR THE IDS PROMPTS, WILL CAUSE THE COORDINATED REPROGRAMMING TO FAIL. THE PCM WILL BE UPDATED BUT THE 1CM WILL NOT BE UPDATED AND NEW FILES WILL NOT BE INSTALLED. IT IS CRITICAL TO FOLLOW THE IDS PROMPTS. SOME VEHICLES MAY REQUIRE SEVERAL DAYS OF DRIVING FOR THE TRANSMISSION TO FULLY ADAPT. REPROGRAMMING CONCERNS/ERRORS MAY BE CAUSED BY THE DATA LINK CONNECTOR (DLC) OR VEHICLE COMMUNICATION MODULE (VCM) BECOMING DISCONNECTED, LOW BATTERIES ON THE INTEGRATED DIAGNOSTIC SYSTEM (IDS) OR THE IDS GOING INTO ANY TYPE OF SLEEP MODE, OR LOW VEHICLE BATTERY VOLTAGE. IF THERE WAS AN INTERRUPTION DURING REPROGRAMMING, MAKE SURE THE ORIGINAL IDS SESSION THAT WAS CREATED FOR THE VEHICLE IS NOT DELETED. IF THE ORIGINAL VEHICLE SESSION IS NOT USED OR DELETED BEFORE THE MODULES ARE COMPLETELY REPROGRAMMED, FURTHER REPROGRAMMING ERRORS CAN OCCUR. THE MODULE RECOVERY PROCEDURE IS NO LONGER AVAILABLE AND IT IS CRITICAL THAT MODULE SWAPPING IS NOT PERFORMED FROM VEHICLE TO VEHICLE. TO REGAIN COMMUNICATION WITH A MODULE THAT HAS BEEN ERASED DURING REPROGRAMMING, RESUME THE ORIGINAL SESSION ONCE THE IDS IS RE-BOOTED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081802A 2004-2006 F-150 0.4 Hr. 4.6L/5.4L, 2006 Mark LT, Econoline 350/450 6.8L 2005-2006 F-Super Duty 6.8L, 2006-2007 Explorer/Mountaineer 4.0L, 2007 Explorer Sport Trac 4.0L, 2006 Mustang 4.OL, 2005-2007 Crown Victoria, Town Car, Grand Marquis: Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Authorization Decal NOT Necessary. (Do Not Use With 9926A, 12650D) 081802A 2006-2007 1.0 Hr. Explorer/Mountaineer 4.6L, 2007 Explorer Sport Trac 4.6L: Check For DICs And Reprogram The PCM And 1CM, Includes Time To Monitor ETC_Trim Value, Authorization Decal NOT Necessary. (Do Not Use With 9926A, 12650D) 081802B 2004-2006 F-150 5.4L, 0.9 Hr. 2006 Mark LT: Check For DTCs And Reprogram The PCM, Includes Time To Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start > Page 3210 Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2004-2006 F-150 4.6L: 0.8 Hr. Check For DTCs And Reprogram The PCM Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2005-2006 Econoline 6.8L: 1.1 Hrs. Check For DTCs And Reprogram The PCM Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2005-2006 F-Super Duty 0.9 Hr. 6.8L: Check For DTCs And Reprogram The PCM Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2006-2007 Explorer, 1.4 Hrs. Mountaineer 2007 Explorer Sport Trac 4.6L: Check For DTCs And Reprogram The PCM And TCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2006-2007 Explorer, 0.8 Hr. Mountaineer 2007 Explorer Sport Trac 4.0L: Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2005-2007 Crown Victoria, 0.8 Hr. Town Car, Grand Marquis: Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start > Page 3211 Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2006 Mustang 4.0L/4.6L: 0.8 Hr. Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3212 Engine Control Module: Locations View 151-1 (Engine Compartment - 4.0L, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3213 View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3216 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3217 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3218 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3219 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3220 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3221 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3222 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3223 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3224 Engine Control Module: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3225 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3226 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3227 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3228 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3229 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3230 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3231 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3232 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3233 Engine Control Module: Connector Views C175B (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3234 C175B (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3235 C175E (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3236 C175E (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3237 C175T (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3238 C175T (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) Engine Control Module: Service and Repair Powertrain Control Module (PCM) POWERTRAIN CONTROL MODULE (PCM) Removal All vehicles 1. NOTE: Powertrain control module (PCM) installation DOES NOT require new keys. Retrieve the module configuration. Carry out the module configuration retrieval steps of the Programmable Module Installation procedure. Vehicles equipped with a 4.6L (3V) engine 2. Remove the air cleaner. All vehicles Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) > Page 3241 3. Disconnect the RH front wheel speed sensor electrical connector. Remove the nuts and position the A/C tube brackets and wiring harness aside. 4. Disconnect the PCM connectors. 5. Remove the bolts and the PCM. Installation All vehicles 1. Install the PCM and bolts. - Tighten to 10 Nm (89 lb-in). 2. Connect the PCM electrical connectors. 3. Position the wiring harness and the A/C tube brackets and install the nuts. Connect the RH front wheel speed sensor electrical connector. - Tighten to 7 Nm (62 lb-in). Vehicles equipped with a 4.6L (3V) engine 4. Install the air cleaner. All vehicles 5. Restore the module configuration. Carry out the module configuration restore steps of the Programmable Module Installation procedure. 6. Reprogram the passive anti-theft system (PATS). Carry out the Parameter Reset procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module (PCM) > Page 3242 Engine Control Module: Service and Repair Flash Electrically Erasable Programmable Read Only Memory (EEPROM) FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) Description The 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 programmed or flashed repeatedly. As part of the calibration there is an area referred to as the vehicle identification (VID) block. The VID block is programmed when installing a new PCM as described under Programming the VID Block for a Replacement PCM. Failure to carry out this procedure may generate DTCs P1635 or P1639. The VID block in an existing PCM can also be tailored to accommodate various hardware or parameter changes made to the vehicle since production. Failure to carry out this procedure properly may generate DTC P1635, Tire/Axle Ratio out of Acceptable Range. An incorrect tire/axle ratio is one of the main causes for DTC P1639. 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 vehicle identification number (VIN), octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control, and 4-wheel drive electronic shift-on-the-fly (ESOF) versus manual shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported by the VID block is displayed on the scan tool. When changing items in the VID block, the strategy places range limits on certain items such as tire and axle ratio. The number of times the VID block may be reconfigured is limited. When this limit is reached, the scan tool displays a message indicating the need to flash the PCM again to reset the VID block. Programming can be carried out by a local Ford dealer or any non-Ford facility. Refer to the scan tool manufacturer's instruction manual for details. Programming the VID Block for a Replacement PCM A new PCM contains the latest strategy and calibration level for a particular vehicle. However, the VID block is blank and needs programming. There are 2 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 is carried out if the old PCM is capable of communicating. This is done by using a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can then be downloaded to the new PCM after it has been installed. Carry out manual data entry if the old module is damaged or incapable of communicating. Remove and install a new PCM. Using a compatible scan tool, select and carry out the module/parameter programming, referring to the scan tool manufacturer's instruction manual. Make certain that all parameters are included. Failure to properly program tire size in revolutions per mile, (rev/mile equals 63,360 divided by the tire circumference in inches), axle ratio, 4x4/4x2, and/or MSOF/ESOF may result in DTCs P1635 and P1639. 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 and Lincoln Mercury technicians, contact your National Hotline or the Professional Technician Society (PTS) website for As-Built data listed under the Service Publications Index. Non-Ford technicians use the Motorcraft(R) website at www.motorcraft.com. From the Motorcraft(R) homepage, use the search function to find the Module Programming or As-Built Data. For Ford and Lincoln Mercury technicians, check the Programmable Module Installation link on the PTS website for quick Programmable Module data information by vehicle. Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate the vehicle hardware. Refer to Module Reprogramming on the scan tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM needs 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 Module Reprogramming on the scan tool. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3246 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations View 151-11 (behind Dash Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3251 C2040 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3252 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The APP sensor is an input to the powertrain control module (PCM) and is used to determine the torque demand. There are 3 pedal position signals in the sensor. Signal 1, APPS1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, APPS2 and APPS3, both have a positive slope (increasing angle, increasing voltage). During normal operation APPS1 is used as the indication of pedal position by the strategy. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. There are 2 reference voltage circuits and 2 signal return circuits for the sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3256 C128 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3257 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW (MAF) SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT Sensor Wire Where Applicable) Terminals Typical Mass Air Flow (MAF) Sensor Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3258 Typical Drop-in Mass Air Flow (MAF) Sensor The 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 the ambient temperature as measured by a constant cold wire. The current required to maintain the temperature of the hot wire is proportional to the mass air 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. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Most MAF sensors have integrated bypass technology with an integrated intake air temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3259 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Disconnect the mass air flow (MAF) sensor electrical connector. 2. Remove the bolts and the MAF. - To install, tighten to 2 Nm (18 lb-in). 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor C180 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 3265 C1366 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 3266 C1367 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3267 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR Typical Synchronizer Hall-Effect CMP Sensor Typical Variable Reluctance CMP Sensor The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to select the correct ignition coil to fire. Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor and the 2-pin connector variable reluctance type sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3268 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation 1. Disconnect the camshaft position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. - To install, tighten to 6 Nm (53 lb-in). 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Description and Operation Clutch Switch: Description and Operation CLUTCH PEDAL POSITION (CPP) SWITCH Typical Clutch Pedal Position (CPP) Switch The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine load. The PCM uses the load information for mass air flow and fuel calculations. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3275 C1064 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3276 Coolant Temperature Sensor/Switch (For Computer): Description and Operation ENGINE COOLANT TEMPERATURE (ECT) SENSOR Typical Thread Type ECT Sensor The ECT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance changes 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 PCM uses the ECT input for fuel control and for cooling fan control. There are 3 types of ECT sensors, threaded, push-in, and twist-lock. The ECT sensor is located in an engine coolant passage. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3277 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR Removal and Installation 1. Drain the cooling system. 2. Disconnect the engine coolant temperature (ECT) sensor electrical connector. 3. Remove the clip and the ECT sensor. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3281 Crankshaft Position Sensor: Diagrams C101 C1120 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3282 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Typical Crankshaft Position (CKP) Sensor The 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 PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L 10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor 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 a fixed reference for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid deceleration between teeth. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3283 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). 4. NOTE: Be sure the sensor wiring is routed away from the battery cable. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Diagrams C107 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Diagrams > Page 3287 Engine Temperature Sensor: Description and Operation CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical CHT Sensor The CHT sensor is a thermistor device in which resistance changes with the temperature. The electrical resistance of a thermistor decreases as temperature increases., and the resistance 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. The CHT sensor is installed in the 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 initiates a fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern 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. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations View 151-14 (Right Front) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3291 Fuel Level Sensor: Diagrams C434A C434B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3292 Fuel Level Sensor: Description and Operation FUEL LEVEL INPUT (FLI) The FLI is a communications network message. Most vehicle applications use a potentiometer type FLI sensor connected to a float in the FP module to determine fuel level. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3293 Fuel Level Sensor: Service and Repair FUEL LEVEL SENSOR Explorer Sport Trac (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3294 Explorer Sport Trac (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3295 Explorer/Mountaineer (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3296 Explorer/Mountaineer (Part 2) All Vehicles (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3297 All Vehicles (Part 2) Removal 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. 1. Remove the fuel pump. 2. NOTE: Note the routing of the sending unit wire for installation. Remove the heat shrink tube covering the electrical connector. 3. Disconnect the electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3298 4. Remove the screw and lift up to remove the fuel gauge sending unit. Installation 1. Route the fuel gauge sending unit wire through the center of the fuel pump module. 2. NOTE: - Both fuel gauge sending wires must be routed behind the metal sending unit plate. - The grounding eyelet must be on the front side of the sending unit. Hook the fuel gauge sending unit on the fuel pump module and install the screw through the grounding eyelet and tighten the screw. 3. Slide the heat shrink tube onto the wire harness and connect the electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3299 4. WARNING: Do not use an open flame to shrink the heat shrink tube, use a heat gun only. Failure to follow these instructions may result in personal injury. Using a heat gun, shrink the heat shrink tube. 5. Install the fuel pump. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE (FTP) SENSOR Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The FTP sensor or in-line FTP sensor is used to measure the fuel tank pressure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Page 3303 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR Removal and Installation WARNING: - The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not present in large quantities, it still presents a danger or 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 cause 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. 1. Remove the evaporative emission (EVAP) canister. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Page 3304 2. Remove the fuel tank shield from the fuel tank. 3. Disconnect the fuel tank pressure sensor electrical connector. 4. Disconnect the 3 fuel tank pressure sensor and tube assembly quick connect couplings from the fuel pump module and the vapor vent valves. 5. Remove the fuel tank pressure sensor and tube assembly. 6. To install, reverse the removal procedure. 7. Leak test the evaporative emission system. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Evaporative Emission System Leak Test 8. Carry out the evaporative emission repair verification drive cycle. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Evaporative Emission Repair Verification Drive Cycle Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3308 C128 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3309 Intake Air Temperature Sensor: Description and Operation INTAKE AIR TEMPERATURE (IAT) SENSOR Typical Stand-Alone/Non-Integrated Intake Air Temperature (IAT) Sensors Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into A Drop-in Or Flange-type MAF Sensor The IAT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance 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 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 air flow. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3310 The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Currently there are 2 design types of IAT sensors used, a stand-alone/non-integrated type and a integrated type. Both types function the same, however the integrated type is incorporated into the mass air flow (MAF) sensor instead of being a stand alone sensor. Supercharged vehicles use 2 IAT sensors. Both sensors are thermistor type devices and operate as described. One is located before the supercharger at the air cleaner for standard OBD/cold weather input, while a second sensor (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 spark and to help determine charge air cooler (CAC) efficiency. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3314 C108 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3315 Knock Sensor: Description and Operation KNOCK SENSOR (KS) Two Types Of Knock Sensor (KS) The KS 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3316 Knock Sensor: Service and Repair KNOCK SENSOR (KS) Removal and Installation 1. Remove the intake manifold. 2. Disconnect the knock sensor (KS) electrical connector. 3. Remove the bolt and the KS. - To install, tighten to 20 Nm (15 lb-ft). 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation Manifold Pressure/Vacuum Sensor: Description and Operation MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR Typical Manifold Absolute Pressure (MAP) Sensor The MAP sensor measures intake manifold absolute pressure. The PCM uses information from the MAP sensor to measure how much exhaust gas is introduced into the intake manifold. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Diagrams C104 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Diagrams > Page 3323 Oil Temperature Sensor For ECM: Description and Operation ENGINE OIL TEMPERATURE (EOT) SENSOR Typical EOT Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance changes 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 EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system. The PCM can use the EOT sensor input to determine the following: - On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM begins reducing power by disabling engine cylinders. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Diagrams > Page 3324 Oil Temperature Sensor For ECM: Service and Repair OIL TEMPERATURE SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine oil. - Install the drain plug and tighten to 26 Nm (19 lb-ft). 3. Disconnect the oil temperature sensor electrical connector. 4. Remove the oil temperature sensor. - To install, tighten to 15 Nm (11 lb-ft). 5. To install, reverse the removal procedure. - Inspect the O-ring seal and install a new O-ring seal if necessary. - Fill the engine with clean engine oil. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3329 View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3330 View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3331 View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 C141 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 3334 C142 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 3335 C171 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 3336 C172 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3337 Oxygen Sensor: Description and Operation HEATED OXYGEN SENSOR (HO2S) Heated Oxygen Sensor (HO2S) The HO2S 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 voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a 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 a temperature of 800°C (1,472°F). At approximately 300°C (572°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater. The PCM turns the heater on by providing the ground when the correct conditions occur. The heater allows the engine to enter closed loop operation sooner. The use of this heater requires the HO2S heater control to be duty cycled, to prevent damage to the heater. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) HEATED OXYGEN SENSOR (HO2S) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3340 Exploded View Special Tool(s) Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If the RH heated oxygen sensor (HO2S) is being serviced, remove the bolts and position the heat shield aside. - To install, tighten to 20 Nm (15 lb-ft). 3. Disconnect the HO2S electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3341 4. NOTE: If necessary, lubricate the HO2S with penetrating and lock lubricant to ease removal. Using the special tool, remove the HO2S. To install, tighten to 41 Nm (30 lb-ft). 5. To install, reverse the removal procedure. - Apply a light coat of nickel anti-seize lubricant to the threads of the HO2S. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3342 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor CATALYST MONITOR SENSOR Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3343 Exploded View Special Tool(s) Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the catalyst monitor sensor electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3344 3. NOTE: If necessary, lubricate the catalyst monitor sensor with penetrating and lock lubricant to ease removal. Using the special tool, remove the catalyst monitor sensor. To install, tighten to 41 Nm (30 lb-ft). 4. To install, reverse the removal procedure. - Apply a light coat of anti-seize lubricant to the threads of the catalyst monitor sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations View 151-2 (Engine Compartment - 4.0L, (2 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 3348 C121 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch POWER STEERING PRESSURE (PSP) SWITCH Typical Power Steering Pressure (PSP) Switch The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch > Page 3351 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor POWER STEERING PRESSURE (PSP) SENSOR Typical Power Steering Pressure (PSP) Sensor The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM changes as the hydraulic pressure changes. The PCM uses the input signal from the PSP sensor to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP sensor signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example, during parking maneuvers. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor The differential pressure feedback EGR sensor 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 EGR sensor receives this signal through 2 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 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. DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR TUBE MOUNTED Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 3355 The tube mounted differential pressure feedback EGR sensor is identical in operation as the large plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 3356 Pressure Feedback Exhaust Sensor: Service and Repair EXHAUST GAS RECIRCULATION (EGR) SYSTEM MODULE Exploded View Removal and Installation 1. Disconnect the exhaust gas recirculation (EGR) system module electrical and vacuum connectors. 2. Disconnect the EGR system module-to-exhaust manifold tube upper fitting. - To install, tighten to 40 Nm (30 lb-ft). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 3357 3. NOTE: When installing the new EGR module gasket, install with the side with the raised circle facing the intake manifold. Remove the bolts, the EGR system module and the gasket. Discard the gasket. To install, tighten to 25 Nm (18 lb-ft). 4. NOTE: The EGR system module sealing surfaces are soft metals. Carefully clean the EGR system module sealing surfaces. 5. To install, reverse the removal procedure. - Install a new EGR system module gasket. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3361 C189 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Electronic Throttle Body (ETB) Position Sensor Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR The ETB position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB position signals are required for increased monitoring. The first ETB position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). During normal operation the negative slope ETB position sensor signal (TP1) is used by the control strategy as the indication of throttle position. The 2 ETB position sensor signals make sure the PCM receives a correct input even if 1 signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Electronic Throttle Body (ETB) Position Sensor > Page 3364 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor THROTTLE POSITION (TP) SENSOR Typical TP Sensor The TP sensor 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 3-blade electrical connector that may be gold plated. The gold plating increases the corrosion resistance on the terminals and increases the connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM from the TP. The operating 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) - throttle angle rate Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3365 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Removal Vehicles equipped with a 4.6L (3V) engine 1. Remove the air cleaner outlet pipe. 2. Remove the bolts and position the heated positive crankcase ventilation (PCV) fitting and hoses aside. - Remove and discard the O-ring seal. All vehicles 3. Disconnect the throttle position (TP) sensor electrical connector. 4. CAUTION: Failure to remove the TP sensor screws in the following manner will result in damage to the screws. First loosen the screws 1-2 full turns using a hand tool and then use a suitable high-speed driver to complete the removal. Remove and discard the 2 screws and the TP sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3366 Installation All vehicles 1. CAUTION: - Do not reuse the TP sensor and screws. A new TP sensor and screws must be installed. - Do not use a high-speed driver to install the new screws or damage to the TP sensor can occur. NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor is aligned with the radial locator hole on the throttle body. Position the new TP sensor and install the 2 new screws. Tighten to 3 Nm (27 lb-in). 2. Connect the TP sensor electrical connector. Vehicles equipped with a 4.6L (3V) engine 3. Install a new O-ring seal, position the heated PCV fitting and install the bolts. 4. Install the air cleaner outlet pipe. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3372 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3373 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3374 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3375 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3376 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3377 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3378 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3379 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3380 Transmission Position Switch/Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3381 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3382 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3383 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3384 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3385 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3386 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3387 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3388 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3389 C167 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3390 Transmission Position Switch/Sensor: Testing and Inspection Digital Transmission Range (TR) Sensor Diagnosis Chart Digital Transmission Range (TR) Sensor Diagnosis Chart Wiggle Test Information for Open/Shorts ^ TR4, TR3A, TR2 and TR1 are all closed in PARK. PARK is a good position to check for intermittent open circuits (with scan tool monitoring TRD). ^ TR4, TR3A, TR2 and TR1 are all open in OVERDRIVE, so OVERDRIVE is a good position to check for shorts to ground. To determine the shorted components while observing TRD, unplug the TR and determine if the short goes away. If the short is still present unplug the transmission harness and determine if the short goes away. If the short is still present, then the short is in the PCM or vehicle harness. Remove the suspect circuit(s) wire terminal from the PCM connector. If the short is still present, then the PCM has an internal failure, otherwise the failure is in the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3391 Transmission Position Switch/Sensor: Adjustments Transmission Range (TR) Sensor Adjustment Special Tool(s) Adjust 1. With the vehicle in NEUTRAL, position it on a hoist For additional information, refer to Maintenance/Service and Repair. 2. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the connector. 4. Disconnect the digital transmission range (TR) sensor electrical connector. 5. Remove the range selector lever cable end from the manual control lever. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3392 6. Remove the outer manual control lever. 7. Loosen but do not remove the digital TR sensor screws. 8. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. ^ Tighten to 8 Nm (71 inch lbs.) 9. Install the outer manual lever. ^ Tighten to 48 Nm (35 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3393 10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable end onto the manual control lever. 11. Reconnect the digital TR sensor electrical connector. 12. Move the rubber boot back over the connector. 13. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3394 14. Verify that the selector lever cable is adjusted correctly. 15. Verify that the vehicle will start in PARK and NEUTRAL and that the reverse lamps illuminate in REVERSE. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3395 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the connector. 4. Disconnect the digital transmission range (TR) sensor electrical connector. 5. Remove the selector lever cable from the manual control lever. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3396 6. Remove the outer manual control lever. 7. Remove the digital TR sensor. Installation 1. CAUTION: The digital transmission range sensor must fit flush against the boss on the case to prevent damage to the sensor. Install the digital TR sensor and 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 be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3397 ^ Tighten to 8 Nm (71 inch lbs.) 3. Install the outer manual lever. ^ Tighten to 48 Nm (35 ft. lbs.) 4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable to the manual control lever. 5. Connect the digital TR sensor electrical connector. 6. Move the rubber boot back over the connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3398 7. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. 8. Verify that the selector lever cable is adjusted correctly. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Output Shaft Speed (OSS) Sensor Vehicle Speed Sensor: Description and Operation Output Shaft Speed (OSS) Sensor OUTPUT SHAFT SPEED (OSS) SENSOR The OSS sensor provides the 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 that is generated. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Output Shaft Speed (OSS) Sensor > Page 3403 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) VEHICLE SPEED SENSOR (VSS) Typical Vehicle Speed Sensor (VSS) The VSS 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3407 C189 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Electronic Throttle Body (ETB) Position Sensor Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR The ETB position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB position signals are required for increased monitoring. The first ETB position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). During normal operation the negative slope ETB position sensor signal (TP1) is used by the control strategy as the indication of throttle position. The 2 ETB position sensor signals make sure the PCM receives a correct input even if 1 signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Electronic Throttle Body (ETB) Position Sensor > Page 3410 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor THROTTLE POSITION (TP) SENSOR Typical TP Sensor The TP sensor 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 3-blade electrical connector that may be gold plated. The gold plating increases the corrosion resistance on the terminals and increases the connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM from the TP. The operating 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) - throttle angle rate Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page 3411 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Removal Vehicles equipped with a 4.6L (3V) engine 1. Remove the air cleaner outlet pipe. 2. Remove the bolts and position the heated positive crankcase ventilation (PCV) fitting and hoses aside. - Remove and discard the O-ring seal. All vehicles 3. Disconnect the throttle position (TP) sensor electrical connector. 4. CAUTION: Failure to remove the TP sensor screws in the following manner will result in damage to the screws. First loosen the screws 1-2 full turns using a hand tool and then use a suitable high-speed driver to complete the removal. Remove and discard the 2 screws and the TP sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page 3412 Installation All vehicles 1. CAUTION: - Do not reuse the TP sensor and screws. A new TP sensor and screws must be installed. - Do not use a high-speed driver to install the new screws or damage to the TP sensor can occur. NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor is aligned with the radial locator hole on the throttle body. Position the new TP sensor and install the 2 new screws. Tighten to 3 Nm (27 lb-in). 2. Connect the TP sensor electrical connector. Vehicles equipped with a 4.6L (3V) engine 3. Install a new O-ring seal, position the heated PCV fitting and install the bolts. 4. Install the air cleaner outlet pipe. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3418 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3419 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3420 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3421 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3422 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3423 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3424 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3425 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3426 Transmission Position Switch/Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3427 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3428 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3429 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3430 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3431 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3432 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3433 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3434 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3435 C167 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3436 Transmission Position Switch/Sensor: Testing and Inspection Digital Transmission Range (TR) Sensor Diagnosis Chart Digital Transmission Range (TR) Sensor Diagnosis Chart Wiggle Test Information for Open/Shorts ^ TR4, TR3A, TR2 and TR1 are all closed in PARK. PARK is a good position to check for intermittent open circuits (with scan tool monitoring TRD). ^ TR4, TR3A, TR2 and TR1 are all open in OVERDRIVE, so OVERDRIVE is a good position to check for shorts to ground. To determine the shorted components while observing TRD, unplug the TR and determine if the short goes away. If the short is still present unplug the transmission harness and determine if the short goes away. If the short is still present, then the short is in the PCM or vehicle harness. Remove the suspect circuit(s) wire terminal from the PCM connector. If the short is still present, then the PCM has an internal failure, otherwise the failure is in the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3437 Transmission Position Switch/Sensor: Adjustments Transmission Range (TR) Sensor Adjustment Special Tool(s) Adjust 1. With the vehicle in NEUTRAL, position it on a hoist For additional information, refer to Maintenance/Service and Repair. 2. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the connector. 4. Disconnect the digital transmission range (TR) sensor electrical connector. 5. Remove the range selector lever cable end from the manual control lever. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3438 6. Remove the outer manual control lever. 7. Loosen but do not remove the digital TR sensor screws. 8. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. ^ Tighten to 8 Nm (71 inch lbs.) 9. Install the outer manual lever. ^ Tighten to 48 Nm (35 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3439 10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable end onto the manual control lever. 11. Reconnect the digital TR sensor electrical connector. 12. Move the rubber boot back over the connector. 13. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3440 14. Verify that the selector lever cable is adjusted correctly. 15. Verify that the vehicle will start in PARK and NEUTRAL and that the reverse lamps illuminate in REVERSE. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3441 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the connector. 4. Disconnect the digital transmission range (TR) sensor electrical connector. 5. Remove the selector lever cable from the manual control lever. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3442 6. Remove the outer manual control lever. 7. Remove the digital TR sensor. Installation 1. CAUTION: The digital transmission range sensor must fit flush against the boss on the case to prevent damage to the sensor. Install the digital TR sensor and 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 be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3443 ^ Tighten to 8 Nm (71 inch lbs.) 3. Install the outer manual lever. ^ Tighten to 48 Nm (35 ft. lbs.) 4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable to the manual control lever. 5. Connect the digital TR sensor electrical connector. 6. Move the rubber boot back over the connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3444 7. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. 8. Verify that the selector lever cable is adjusted correctly. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 C1451 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 > Page 3449 C1452 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Page 3450 Variable Valve Timing Actuator: Description and Operation VARIABLE CAMSHAFT TIMING (VCT) SYSTEM Overview The VCT enables rotation of the camshaft(s) relative to the crankshaft rotation as a function of engine operating conditions. There are 4 types of VCT systems. Exhaust phase shifting (EPS) system - the exhaust cam is the active cam being retarded. - Intake phase shifting (IPS) system - the intake cam is the active cam being advanced. - Dual equal phase shifting (DEPS) system - both intake and exhaust cams are phase shifted and equally advanced or retarded. - Dual independent phase shifting (DIPS) system - where both the intake and exhaust cams are shifted independently. All systems have 4 operational modes: idle, part throttle, wide open throttle (WOT), and default mode. At idle and low engine speeds with closed throttle, the powertrain control module (PCM) determines the phase angle based on air flow, engine oil temperature and engine coolant temperature. At part and wide open throttle the PCM determines the phase angle based on engine RPM, load, and throttle position. VCT systems provide reduced emissions and enhanced engine power, fuel economy and idle quality. IPS systems also have the added benefit of improved torque. In addition, some VCT system applications can eliminate the need for an external exhaust gas recirculation (EGR) system. The elimination of the EGR system is accomplished by controlling the overlap time between the intake valve opening and exhaust valve closing. Currently, both the IPS and DEPS systems are used. Variable Camshaft Timing (VCT) System VCT System The VCT system consists of an electric hydraulic positioning control solenoid, a camshaft position (CMP) sensor, and a trigger wheel. The CMP trigger wheel has a number of equally spaced teeth equal to the number (n) of cylinders on a bank plus one extra tooth (n+1). Four cylinder and V8 engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1 tooth trigger wheel. The extra tooth placed between the equally spaced teeth represents the CMP signal for that bank. A crankshaft position sensor (CKP) provides the PCM with crankshaft positioning information in 10 degree increments. 1. The PCM receives input signals from the intake air temperature (IAT) sensor, engine coolant temperature (ECT) sensor, engine oil temperature (EOT) sensor, CMP, throttle position (TP) sensor, mass air flow (MAF) sensor, and CKP to determine the operating conditions of the engine. At idle and low engine speeds with closed throttle, the PCM controls the camshaft position based on ECT, EOT, IAT, and MAF. During part and wide open throttle, the camshaft position is determined by engine RPM, load and throttle position. The VCT system does not operate until the engine is at normal operating temperature. 2. The VCT system is enabled by the PCM when the correct conditions are met. 3. The CKP signal is used as a reference for CMP positioning. 4. The VCT solenoid valve is an integral part of the VCT system. The solenoid valve controls the flow of engine oil in the VCT actuator assembly. As the PCM controls the duty cycle of the solenoid valve, oil pressure/flow advances or retards the cam timing. Duty cycles near 0% or 100% represent rapid movement of the camshaft. Retaining a fixed camshaft position is accomplished by dithering (oscillating) the solenoid valve duty cycle. The PCM calculates and determines the desired camshaft position. It continually updates the VCT solenoid duty cycle until the desired position is achieved. A difference between the desired and actual camshaft position represents a position error in the PCM VCT control loop. The PCM disables the VCT and places the camshaft in a default position if a concern is detected. A related DTC is also set when the concern is detected. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Diagrams > Page 3451 5. When the VCT solenoid is energized, engine oil is allowed to flow to the VCT actuator assembly which advances or retards the camshaft timing. One half of the VCT actuator is coupled to the camshaft and the other half is connected to the timing chain. Oil chambers between the 2 halves couple the camshaft to the timing chain. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the camshaft to rotate in either an advance or retard position depending on the oil flow. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Service and Repair Variable Valve Timing Solenoid: Service and Repair VARIABLE CAMSHAFT TIMING (VCT) OIL CONTROL SOLENOID Removal and Installation 1. Remove the valve cover. 2. Remove the bolt and the VCT oil control solenoid. - To install, tighten to 5 Nm (44 lb-in). 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Output Shaft Speed (OSS) Sensor Vehicle Speed Sensor: Description and Operation Output Shaft Speed (OSS) Sensor OUTPUT SHAFT SPEED (OSS) SENSOR The OSS sensor provides the 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 that is generated. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Output Shaft Speed (OSS) Sensor > Page 3459 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) VEHICLE SPEED SENSOR (VSS) Typical Vehicle Speed Sensor (VSS) The VSS 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Solenoid > Component Information > Description and Operation Air Diverter Solenoid: Description and Operation SECONDARY AIR INJECTION (AIR) BYPASS SOLENOID Secondary AIR Bypass Solenoid The secondary AIR bypass solenoid is used by the PCM to control vacuum to the secondary air injection diverter (AIR diverter) valve. The secondary AIR bypass solenoid is a normally closed solenoid. The secondary AIR bypass solenoid also has a filtered vent feature to permit vacuum release. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve > Component Information > Description and Operation Air Diverter Valve: Description and Operation SECONDARY AIR DIVERTER VALVE Secondary AIR Diverter Valve The secondary AIR diverter valve is used with the secondary AIR pump to provide on/off control of air to the exhaust manifold and catalytic converter. When the secondary AIR pump is on and vacuum is supplied to the AIR diverter valve, air passes the integral check valve disk. When the secondary 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 system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump > Component Information > Description and Operation Air Injection Pump: Description and Operation SECONDARY AIR PUMP Secondary Air Pump The secondary AIR pump provides pressurized air to the secondary AIR system. The secondary AIR pump functions independently of RPM and is controlled by the PCM. The secondary 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 secondary AIR pump draws dry filtered air from the intake air system downstream of the MAF/IAT sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation Catalytic Converter: Description and Operation CATALYST AND EXHAUST SYSTEMS Overview V-Engines In-Line Engines The catalytic converter and exhaust Systems 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). The major air pollutants of CO, NOx, and HCs, and their emission into the atmosphere must be controlled. The exhaust system generally consists of an exhaust manifold, front exhaust pipe, front heated oxygen sensor (HO2S), rear exhaust pipe, catalyst HO2S, a muffler, and an exhaust tailpipe. The catalytic converter is typically installed between the front and rear exhaust pipes. On some vehicle applications, more than one catalyst is used between the front and rear exhaust pipes. Catalytic converter efficiency is monitored by the on board diagnostic (OBD) system strategy in the PCM. For information on the OBD catalyst monitor, refer to the description for the Catalyst Efficiency Monitor. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes/Monitors/Catalyst Efficiency Monitor The number of HO2Ss used in the exhaust stream and the location of these sensors depend on the vehicle emission certification level (LEV, LEV-II, ULEV, PZEV). On most vehicles only 2 HO2Ss are used in an exhaust stream. The front sensors (HO2S11/HO2S21) before the catalyst are used for primary fuel control while the ones after the catalyst (HO2S12/HO2S22) are used to monitor catalyst efficiency. However, some partial zero emission vehicles (PZEV) use 3 HO2Ss for each engine bank. The stream 1 sensors (HO2S11/HO2S21) located before the catalyst are used for primary fuel control, the stream 2 sensors (HO2S12/HO2S22) are used to monitor the light-off catalyst, and the stream 3 sensors (HO2S13/HO2S23) located after the catalyst are used for long term fuel trim control to optimize catalyst efficiency (fore aft oxygen sensor control). Current PZEV vehicles use only a 4-cylinder engine, so only the bank 1 HO2Ss are used. Catalytic Converter Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 3474 A catalyst is a material that remains unchanged when it initiates and increases the speed of a chemical reaction. A catalyst also enables 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 ceramic 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. Light Off Catalyst As the catalyst heats up, converter efficiency rises rapidly. The point at which conversion efficiency exceeds 50% is called catalyst light off. For most catalysts this point occurs at 246°C to 302°C (475°F to 575°F). A fast light catalyst is a 3-way catalyst (TWC) that is located as close to the exhaust manifold as possible. Because the light off catalyst is located close to the exhaust manifold it lights off faster and reduces emissions more quickly than the catalyst located under the body. Once the catalyst lights off, the catalyst quickly reaches the maximum conversion efficiency for that catalyst. Three-Way Catalyst (TWC) Conversion Efficiency TWC Conversion Efficiency Chart A TWC requires a stoichiometric fuel ratio, 14.7 pounds of air to 1 pound of fuel (14.7:1), for high conversion efficiency. In order to achieve these high efficiencies, the air/fuel ratio must be tightly controlled with a narrow window of stoichiometry. Deviations outside of this window greatly decrease the conversion efficiency. For example a rich mixture decreases the HC and CO conversion efficiency while a lean mixture decreases the NOx conversion efficiency. Exhaust System Typical Bank 1 Catalyst 2 HO2S Configuration Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 3475 Typical Bank 1 Catalyst 3 HO2S Configuration 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. A HO2S is mounted on the front exhaust pipe before the catalyst. The catalytic converter reduces the concentration of CO, unburned HCs, and NOx in the exhaust emissions to an acceptable level. The reduced exhaust emissions are directed from the catalytic converter past another HO2S mounted in the rear exhaust pipe and then on into the muffler. Finally, the exhaust emissions are directed to the atmosphere through an exhaust tailpipe. On some PZEV, there is a total of 3 HO2S in the exhaust stream. One near the exhaust manifold (stream 1), one in the middle of the light-off catalyst (stream 2), and the third (stream 3) is mounted after the light-off catalyst. Underbody Catalyst The underbody catalyst is located after the light off catalyst. The underbody catalyst may be in line with the light off catalyst, or the underbody catalyst may be common to 2 light off catalysts, forming a Y pipe configuration. For an exact configuration of the catalyst and exhaust system for a specific vehicle, refer to Catalytic Converter, Exhaust System. Three-Way Catalytic (TWC) Converter The 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 NOx. The 3-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. 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. Heated Oxygen Sensor (HO2S) The HO2Ss provide the powertrain control module (PCM) with voltage and frequency information related to the oxygen content of the exhaust gas. 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 also reduces the noise produced by exhaust gases as they travel from the catalytic converter to the atmosphere. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams C1195 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Page 3480 Canister Purge Control Valve: Description and Operation EVAPORATIVE EMISSION (EVAP) CANISTER PURGE VALVE Typical EVAP Canister Purge Valve NOTE: The EVAP canister purge valve may also be referred to as a vapor management valve (VMV). The EVAP canister purge valve is 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 a normally closed valve. The EVAP canister purge valve controls the flow of vapors by way of a solenoid, eliminating the need for an electronic vacuum regulator and vacuum diaphragm. The PCM outputs a signal between 0 mA and 1,000 mA to control the EVAP canister purge valve. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Page 3481 Canister Purge Control Valve: Service and Repair EVAPORATIVE EMISSION CANISTER PURGE VALVE Removal and Installation 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 vapors 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. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Disconnect the evaporative emission (EVAP) canister purge valve electrical connector. 4. Disconnect the 2 vapor tube quick connect couplings from the EVAP canister purge valve. 5. Detach the EVAP canister purge valve from the bracket and remove. 6. To install, reverse the removal procedure. 7. Leak test the evaporative emission system. See: Testing and Inspection/Evaporative Emission System Leak Test 8. Carry out the evaporative emission repair verification drive cycle. See: Testing and Inspection/Evaporative Emission Repair Verification Drive Cycle Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 DUST SEPARATOR Removal and Installation 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 can 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. NOTE: Use only water-based lubricants on the vapor hoses. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Disconnect the fuel vapor hose from the dust separator. 4. Disconnect the fuel filler pipe vapor hose from the dust separator. 5. Remove the bolt and the dust separator. - To install, tighten to 9 Nm (80 lb-in). 6. To install, reverse the removal procedure. - Lubricate the vapor hoses with a water-based lubricant to ease installation. 7. Leak test the evaporative emission system. See: Testing and Inspection/Evaporative Emission System Leak Test 8. Carry out the evaporative emission repair drive cycle. See: Testing and Inspection/Evaporative Emission Repair Verification Drive Cycle Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair Evaporative Emission Control Canister: Service and Repair EVAPORATIVE EMISSION CANISTER Removal and Installation 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. NOTE: Use only water-based lubricants on the vapor hoses. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the fuel tank. 4. Detach the evaporative emission (EVAP) canister from the fuel tank to gain access to the quick connect coupling. 5. Disconnect the fuel tank pressure sensor and tube assembly quick connect coupling from the EVAP canister. 6. Disconnect the vapor hose from the EVAP canister. 7. Remove the EVAP canister. 8. To install, reverse the removal procedure. - Lubricate the vapor hoses with a water-based lubricant to ease installation. 9. Leak test the evaporative emission system. See: Testing and Inspection/Evaporative Emission System Leak Test 10. Carry out the evaporative emission repair verification drive cycle. See: Testing and Inspection/Evaporative Emission Repair Verification Drive Cycle Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Diagrams C450 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Diagrams > Page 3491 Leak Detection Valve: Description and Operation CANISTER VENT (CV) SOLENOID Typical Canister Vent (CV) Solenoid During the evaporative emissions (EVAP) leak check monitor, the CV solenoid seals the EVAP canister from the atmospheric pressure. This allows the EVAP canister purge valve to obtain the target vacuum in the fuel tank during the EVAP leak check monitor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid Vapor Separator, Evaporative System > Component Information > Service and Repair Liquid Vapor Separator: Service and Repair FUEL VAPOR VENT VALVE Removal and Installation 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 can 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. NOTE: Use only water-based lubricants on the vapor hoses. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Disconnect the fuel vapor vent valve electrical connector. 4. Disconnect the fuel vapor hoses from the fuel vapor vent valve and remove the fuel vapor vent valve. 5. To install, reverse the removal procedure. - Lubricate the vapor hoses with a water-based lubricant to ease installation. 6. Leak test the evaporative emission system. See: Testing and Inspection/Evaporative Emission System Leak Test 7. Carry out the evaporative emission repair drive cycle. See: Testing and Inspection/Evaporative Emission Repair Verification Drive Cycle Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Module > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Module > Component Information > Locations > Page 3499 C1450 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Service and Repair EGR Control Solenoid: Service and Repair EXHAUST GAS RECIRCULATION (EGR) SYSTEM MODULE Exploded View Removal and Installation 1. Disconnect the exhaust gas recirculation (EGR) system module electrical and vacuum connectors. 2. Disconnect the EGR system module-to-exhaust manifold tube upper fitting. - To install, tighten to 40 Nm (30 lb-ft). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Service and Repair > Page 3503 3. NOTE: When installing the new EGR module gasket, install with the side with the raised circle facing the intake manifold. Remove the bolts, the EGR system module and the gasket. Discard the gasket. To install, tighten to 25 Nm (18 lb-ft). 4. NOTE: The EGR system module sealing surfaces are soft metals. Carefully clean the EGR system module sealing surfaces. 5. To install, reverse the removal procedure. - Install a new EGR system module gasket. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Description and Operation EGR Electronic Vacuum Regulator Solenoid: Description and Operation EXHAUST GAS RECIRCULATION (EGR) VACUUM REGULATOR SOLENOID EGR Vacuum Regulator Solenoid Vacuum Output (IN-HG) EGR Vacuum Regulator Solenoid Data The EGR vacuum regulator solenoid is an electromagnetic device 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Description and Operation EGR Tube: Description and Operation EXHAUST GAS RECIRCULATION (EGR) ORIFICE TUBE ASSEMBLY EGR Orifice Tube Assembly The orifice tube assembly 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 2 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Description and Operation > Page 3510 EGR Tube: Service and Repair EXHAUST GAS RECIRCULATION (EGR) SYSTEM MODULE TUBE Exploded View Removal and Installation 1. Disconnect the exhaust gas recirculation (EGR) system module-to-exhaust manifold tube upper fitting. - To install, tighten to 40 Nm (30 lb-ft). 2. Disconnect the EGR system module-to-exhaust manifold tube lower fitting and remove the tube. - To install, tighten to 40 Nm (30 lb-ft). 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Electric Exhaust Gas Recirculation (EEGR) Valve EGR Valve: Description and Operation Electric Exhaust Gas Recirculation (EEGR) Valve ELECTRIC EXHAUST GAS RECIRCULATION (EEGR) VALVE EEGR Motor/Valve Assembly Depending on the application, the EEGR valve is a water cooled or an air cooled motor/valve assembly. The motor is commanded to move in 52 discrete steps as it acts directly on the EEGR valve. The position of the valve determines the rate of EGR. The built-in spring works to close the valve (against the motor opening force). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Electric Exhaust Gas Recirculation (EEGR) Valve > Page 3515 EGR Valve: Description and Operation Exhaust Gas Recirculation (EGR) System Module (ESM) EXHAUST GAS RECIRCULATION (EGR) SYSTEM MODULE (ESM) ESM The ESM is an integrated differential pressure feedback EGR system that functions in the same manner as a conventional differential pressure feedback EGR system. The various system components have been integrated into a single component called the ESM. The flange of the valve portion of the ESM bolts directly to the intake manifold with a metal gasket that forms the metering orifice. This arrangement increases system reliability, response time, and system precision. By relocating the EGR orifice from the exhaust to the intake side of the EGR valve, the downstream pressure signal measures manifold absolute pressure (MAP). This MAP signal is used for EGR correction and inferred barometric pressure (BARO) at key on. The system provides the powertrain control module (PCM) with a differential pressure feedback EGR signal, identical to a traditional differential pressure feedback EGR system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Electric Exhaust Gas Recirculation (EEGR) Valve > Page 3516 EGR Valve: Description and Operation Exhaust Gas Recirculation (EGR) Valve EXHAUST GAS RECIRCULATION (EGR) VALVE Typical EGR Valve EGR Flowrate The EGR valve in the differential pressure feedback EGR system is a conventional, vacuum-actuated. The valve increases or decreases the flow of EGR. 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 repair specifications on flow rate is impractical. The on board diagnostic (OBD) system monitors the EGR valve function and triggers a diagnostic trouble code (DTC) if the test criteria is not met. The EGR valve flow rate is not measured directly as part of the diagnostic procedures. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Page 3517 EGR Valve: Service and Repair EXHAUST GAS RECIRCULATION (EGR) SYSTEM MODULE Exploded View Removal and Installation 1. Disconnect the exhaust gas recirculation (EGR) system module electrical and vacuum connectors. 2. Disconnect the EGR system module-to-exhaust manifold tube upper fitting. - To install, tighten to 40 Nm (30 lb-ft). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Page 3518 3. NOTE: When installing the new EGR module gasket, install with the side with the raised circle facing the intake manifold. Remove the bolts, the EGR system module and the gasket. Discard the gasket. To install, tighten to 25 Nm (18 lb-ft). 4. NOTE: The EGR system module sealing surfaces are soft metals. Carefully clean the EGR system module sealing surfaces. 5. To install, reverse the removal procedure. - Install a new EGR system module gasket. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor The differential pressure feedback EGR sensor 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 EGR sensor receives this signal through 2 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 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. DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR TUBE MOUNTED Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 3522 The tube mounted differential pressure feedback EGR sensor is identical in operation as the large plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 3523 Pressure Feedback Exhaust Sensor: Service and Repair EXHAUST GAS RECIRCULATION (EGR) SYSTEM MODULE Exploded View Removal and Installation 1. Disconnect the exhaust gas recirculation (EGR) system module electrical and vacuum connectors. 2. Disconnect the EGR system module-to-exhaust manifold tube upper fitting. - To install, tighten to 40 Nm (30 lb-ft). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 3524 3. NOTE: When installing the new EGR module gasket, install with the side with the raised circle facing the intake manifold. Remove the bolts, the EGR system module and the gasket. Discard the gasket. To install, tighten to 25 Nm (18 lb-ft). 4. NOTE: The EGR system module sealing surfaces are soft metals. Carefully clean the EGR system module sealing surfaces. 5. To install, reverse the removal procedure. - Install a new EGR system module gasket. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Diagrams C190 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Diagrams > Page 3529 Positive Crankcase Ventilation Valve: Service and Repair POSITIVE CRANKCASE VENTILATION (PCV) VALVE Removal and Installation 1. Disconnect the PCV valve electrical connector. 2. Disconnect the PCV valve hose. 3. NOTE: If the PCV valve is removed from the valve cover, a new PCV valve must be installed. Rotate the PCV valve counterclockwise and remove it from the valve cover. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Relays and Modules - Emission Control Systems > EGR Control Module > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Relays and Modules - Emission Control Systems > EGR Control Module > Component Information > Locations > Page 3534 C1450 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor The differential pressure feedback EGR sensor 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 EGR sensor receives this signal through 2 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 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. DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR TUBE MOUNTED Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 3539 The tube mounted differential pressure feedback EGR sensor is identical in operation as the large plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 3540 Pressure Feedback Exhaust Sensor: Service and Repair EXHAUST GAS RECIRCULATION (EGR) SYSTEM MODULE Exploded View Removal and Installation 1. Disconnect the exhaust gas recirculation (EGR) system module electrical and vacuum connectors. 2. Disconnect the EGR system module-to-exhaust manifold tube upper fitting. - To install, tighten to 40 Nm (30 lb-ft). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 3541 3. NOTE: When installing the new EGR module gasket, install with the side with the raised circle facing the intake manifold. Remove the bolts, the EGR system module and the gasket. Discard the gasket. To install, tighten to 25 Nm (18 lb-ft). 4. NOTE: The EGR system module sealing surfaces are soft metals. Carefully clean the EGR system module sealing surfaces. 5. To install, reverse the removal procedure. - Install a new EGR system module gasket. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Item....................................................................................................................................................... ..............................................................Specification Fuel Pressure Key on, engine off................................................................................................................................. .............................................207-276 kPa (30-40 psi) Engine running................................................. ..................................................................................................................................207-276 kPa (30-40 psi) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE 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. - 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, which can cause a fire hazard. Failure to follow these instructions may result in personal injury. 1. NOTE: The front passenger door frame scuff plate is retained only by internal metal clips. Remove the front passenger door frame scuff plate. 2. NOTE: - The front passenger door side interior kick panel is retained only by internal metal clips. - It may be necessary to reposition the lower end of the door jam weather stripping to remove the front passenger door side interior kick panel. Remove the front passenger side interior kick panel. 3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Start the engine and allow it to idle until it stalls. 5. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail pressure has been released. 6. Turn the ignition switch to the OFF position. 7. When the fuel system service is complete, reconnect the IFS switch electrical connector. 8. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 9. Start the vehicle and check the fuel system for leaks. 10. Install the front passenger side interior kick panel. 11. Install the front passenger door frame scuff plate. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Hot Idle Speed ..................................................................................................................................... ............................................................ 750-820 RPM Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications Torque Specifications Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 3555 Accelerator Pedal: Description and Operation Adjustable Pedals Using the adjustable pedal switch located on the instrument panel, the driver can adjust the brake and accelerator pedals for a more comfortable driving position. For removal and installation of the adjustable pedals, refer to Brake Pedal and Bracket. Adjustable Pedal Operation The adjustable pedals with or without memory feature are operational with the ignition switch in the ON or OFF position. The pedals are adjusted forward or rearward using the adjustable pedal switch. Memory Adjustable Pedal Operation The adjustable pedals with memory feature is controlled by using the memory switches or the remote keyless entry (RKE) transmitter. The exterior mirror and power driver seat positions are also stored and recalled with the power adjustable pedal positions. The system can store 3 memory settings. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Accelerator Pedal - Fixed Accelerator Pedal: Service and Repair Accelerator Pedal - Fixed ACCELERATOR PEDAL - FIXED Removal and Installation 1. Disconnect the accelerator pedal electrical connector. 2. Remove the nuts and the accelerator pedal assembly. - To install, tighten to 7 Nm (62 lb-in). 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Accelerator Pedal - Fixed > Page 3558 Accelerator Pedal: Service and Repair Accelerator Pedal - Adjustable ACCELERATOR PEDAL - ADJUSTABLE Removal and Installation 1. The adjustable accelerator pedal and adjustable brake pedal must be serviced as a unit. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations View 151-11 (behind Dash Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3562 C2040 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3563 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The APP sensor is an input to the powertrain control module (PCM) and is used to determine the torque demand. There are 3 pedal position signals in the sensor. Signal 1, APPS1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, APPS2 and APPS3, both have a positive slope (increasing angle, increasing voltage). During normal operation APPS1 is used as the indication of pedal position by the strategy. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. There are 2 reference voltage circuits and 2 signal return circuits for the sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair AIR CLEANER ELEMENT Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 3568 Exploded View Removal and Installation NOTE: Do not disconnect the mass air flow (MAF) sensor electrical connector. Vehicles equipped with a 4.0L (SOHC) engine 1. Detach the wiring harness retainer from the air cleaner outlet pipe. Vehicles equipped with a 4.6L (3V) engine Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 3569 2. Detach the wiring harness retainer from the coolant expansion tank. All vehicles 3. Loosen the clamp and disconnect the air cleaner outlet pipe from the air cleaner. 4. Unclip and remove the air cleaner cover. 5. Remove the air cleaner element. 6. NOTE: Clean the inside of the air cleaner tray. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3573 C128 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3574 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW (MAF) SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT Sensor Wire Where Applicable) Terminals Typical Mass Air Flow (MAF) Sensor Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3575 Typical Drop-in Mass Air Flow (MAF) Sensor The 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 the ambient temperature as measured by a constant cold wire. The current required to maintain the temperature of the hot wire is proportional to the mass air 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. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Most MAF sensors have integrated bypass technology with an integrated intake air temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3576 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Disconnect the mass air flow (MAF) sensor electrical connector. 2. Remove the bolts and the MAF. - To install, tighten to 2 Nm (18 lb-in). 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap Warning Indicator > Component Information > Description and Operation Fuel Filler Cap Warning Indicator: Description and Operation CHECK FUEL CAP INDICATOR The check fuel cap indicator is a communications network message sent by the PCM. The PCM sends the message to illuminate the lamp when the strategy determines that there is a failure in the vapor management system due to the fuel filler cap not being sealed correctly. This would be detected by the inability to pull vacuum in the fuel tank, after a fueling event. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE 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. - 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, which can cause a fire hazard. Failure to follow these instructions may result in personal injury. 1. NOTE: The front passenger door frame scuff plate is retained only by internal metal clips. Remove the front passenger door frame scuff plate. 2. NOTE: - The front passenger door side interior kick panel is retained only by internal metal clips. - It may be necessary to reposition the lower end of the door jam weather stripping to remove the front passenger door side interior kick panel. Remove the front passenger side interior kick panel. 3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Start the engine and allow it to idle until it stalls. 5. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail pressure has been released. 6. Turn the ignition switch to the OFF position. 7. When the fuel system service is complete, reconnect the IFS switch electrical connector. 8. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 9. Start the vehicle and check the fuel system for leaks. 10. Install the front passenger side interior kick panel. 11. Install the front passenger door frame scuff plate. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications Fuel Injector: Electrical Specifications Resistance ........................................................................................................................................... ............................................................. 11 - 18 Ohms Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 C181 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3590 C182 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3591 C183 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3592 C184 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3593 Fuel Injector: Diagrams C181 C182 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3594 C183 C184 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3595 C185 C186 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 3596 Fuel Injector: Description and Operation FUEL INJECTORS Typical Fuel Injector CAUTION: Do not apply battery positive voltage (B+) directly to the fuel injector electrical connector terminals. The solenoids may be damaged internally in a matter of seconds. The fuel injector is a solenoid-operated valve that meters fuel flow to the engine. The fuel injector is opened and closed a constant number of times per crankshaft revolution. The amount of fuel is controlled by the length of time the fuel injector is held open. The fuel injector is normally closed, and is operated by a 12-volt source from either the electronic engine control (EEC) power relay or fuel pump relay. The ground signal is controlled by the PCM. The injector is the deposit resistant injector (DRI) type and does not have to be cleaned. However, it can be flow checked and, if found outside of specification, a new fuel injector should be installed. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 3597 Fuel Injector: Service and Repair FUEL INJECTORS Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 3598 Part 2 Exploded View Removal and Installation 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. NOTE: During the repair or replacement of fuel-related components, cap, tape or otherwise appropriately protect all liquid and vapor fuel openings to prevent the ingress of dirt or other contamination. Remove all caps, tape and other protective materials prior to installation. 1. Remove the fuel rail. 2. Remove the fuel injectors and the fuel injector O-ring seals. 3. CAUTION: O-ring seals 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: Install new fuel injector-to-fuel rail O-ring seals and lubricate them with clean engine oil. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings Fuel Line Coupler: Service and Repair Spring Lock Couplings SPRING LOCK COUPLINGS Special Tool(s) Special Tool(s) Disconnect - Type I 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 can 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 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, which can cause a fire hazard. Failure to follow these instructions may result in personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. - This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury. CAUTION: - If the liquid or vapor tube is damaged (torn, holes or delaminated), a new tube assembly must be installed. Do not use aftermarket sleeving. Do not re-adhere loose sleeving material. - Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or tubes. - When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube. - Do not use any tools. Use of tools may cause a deformity in the coupling components which can cause fuel leaks. NOTE: During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor openings shall be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials shall be removed prior to installation. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3603 3. Disconnect the safety clip from the fuel tube. 4. Install the special tool and press it into the spring lock coupling. 5. Separate the spring lock coupling. Connect - Type I 1. Inspect and clean both spring lock coupling ends. 2. CAUTION: Make sure the fuel tube clicks into place when installing the tube. To make sure that the fuel tube is fully seated, pull on the tube. NOTE: Lubricate the spring lock coupling with clean engine oil. Align the fuel tube spring lock coupling and push together until a click is heard. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3604 3. Pull on the spring lock coupling to make sure it is fully seated. Install the safety clip. Disconnect - Type II 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 can 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 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, which can cause a fire hazard. Failure to follow these instructions may result in personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. - This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury. CAUTION: - If the liquid or vapor tube is damaged (torn, holes or delaminated), a new tube assembly must be installed. Do not use aftermarket sleeving. Do not re-adhere loose sleeving material. - Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or tubes. - When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube. - Do not use any tools. Use of tools may cause a deformity in the coupling components which can cause fuel leaks. NOTE: During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor openings shall be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials shall be removed prior to installation. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Remove the fuel tube clip. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3605 4. Install the special tool. 5. Close and push the special tool into the open side of the cage. 6. Separate the spring lock coupling. Connect - Type II 1. NOTE: Apply clean engine oil to O-ring seals. Inspect and clean both spring lock coupling ends. Install new O-ring seals and garter springs if necessary. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3606 2. CAUTION: Make sure the fuel tube clicks into place when installing the tube. To make sure that the fuel tube is fully seated, pull on the tube. Fit the male end into the female end and push until the garter spring snaps over the flared end of the female end. 3. Make sure the spring lock coupling is engaged by pulling on the lines and install the safety clip. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3607 Fuel Line Coupler: Service and Repair Quick Connect Coupling QUICK CONNECT COUPLING Disconnect - Type I 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. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, which can cause a fire hazard. Failure to follow these instructions may result in personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. - This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury. CAUTION: - If the liquid or vapor tube is damaged (torn, holes or delaminated), a new tube assembly must be installed. Do not use aftermarket sleeving. Do not re-adhere loose sleeving material. - Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or tubes. - When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube. Apply clean engine oil to the end of the tube before inserting the tube into the connector. - Do not use any tools. Use of tools may cause a deformity in the coupling components which can cause fuel leaks. NOTE: During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor openings shall be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials shall be removed prior to installation. 1. If servicing a liquid fuel tube, release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Unclip the locking tab. 4. Depress the tabs and press the clip downward. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3608 5. Separate the quick connect coupling. Connect - Type I 1. Inspect the quick connect coupling and the tube for damage. Remove any dirt or obstructions. 2. CAUTION: Make sure the fuel tube clicks into place when installing the tube. To make sure that the fuel tube is fully seated, pull on the tube. NOTE: Lubricate the quick connect coupling with clean engine oil. Connect the quick connect coupling. 3. Push the clip up into the quick connect coupling. Pull on the tube to make sure it is seated correctly. 4. Clip the locking tab in place. Disconnect - Type II Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3609 WARNING: - The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not present in large quantities, it still presents 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. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, which can cause a fire hazard. Failure to follow these instructions may result in personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. - This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury. CAUTION: - If the liquid or vapor tube is damaged (torn, holes or delaminated), a new tube assembly must be installed. Do not use aftermarket sleeving. Do not re-adhere loose sleeving material. - Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or tubes. - When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube. Apply clean engine oil to the end of the tube before inserting the tube into the connector. - Do not use any tools. Use of tools may cause a deformity in the coupling components which can cause fuel leaks. NOTE: During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor openings shall be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials shall be removed prior to installation. 1. If servicing a liquid fuel tube, release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel tube quick connect coupling. - Press the fuel tube quick connect coupling button and pull the fuel tube to disconnect. Connect - Type II 1. Inspect the quick connect coupling and the tube for damage. Remove any dirt or obstructions. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3610 2. CAUTION: Make sure the fuel tube clicks into place when installing the tube. To make sure that the fuel tube is fully seated, pull on the tube. NOTE: Apply clean engine oil to O-ring seals. Install the quick connect coupling onto the tube until it is fully seated. Disconnect - Type III WARNING: - The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not present in large quantities, it still presents 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. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, which can cause a fire hazard. Failure to follow these instructions may result in personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. CAUTION: - If the liquid or vapor tube is damaged (torn, holes or delaminated), a new tube assembly must be installed. Do not use aftermarket sleeving. Do not re-adhere loose sleeving material. - Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or tubes. - When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube. Apply clean engine oil to the end of the tube before inserting the tube into the connector. - Do not use any tools. Use of tools may cause a deformity in the coupling components which can cause fuel leaks. NOTE: During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor openings shall be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials shall be removed prior to installation. 1. Disconnect the battery ground cable. 2. Release the locking tab on the quick connect coupling. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3611 3. Separate the quick connect coupling from the fitting. Connect - Type III 1. Inspect the quick connect coupling and the tube for damage. Remove any dirt or obstructions. 2. CAUTION: Make sure the fuel tube clicks into place when installing the tube. To make sure that the fuel tube is fully seated, pull on the tube. NOTE: Apply clean engine oil to O-ring seals. Release the locking tab and install the quick connect coupling onto the fitting. 3. Position the locking tab into the latched position. Disconnect - Type IV WARNING: - The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not present in large quantities, it still presents 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. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, which can cause a fire hazard. Failure to follow these instructions may result in personal injury. - Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3612 fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. - This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury. CAUTION: - If the liquid or vapor tube is damaged (torn, holes or delaminated), a new tube assembly must be installed. Do not use aftermarket sleeving. Do not re-adhere loose sleeving material. - Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or tubes. - When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube. Apply clean engine oil to the end of the tube before inserting the tube into the connector. - Do not use any tools. Use of tools may cause a deformity in the coupling components which can cause fuel leaks. NOTE: During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor openings shall be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials shall be removed prior to installation. 1. If servicing a liquid fuel tube, release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Compress the clip legs and push the clip into the quick connect coupling. 4. Separate the quick connect coupling from the tube. Connect - Type IV 1. Inspect the quick connect coupling and the tube for damage. Remove any dirt or obstructions. 2. CAUTION: Make sure the fuel tube clicks into place when installing the tube. To make sure that the fuel tube is fully seated, pull on the Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3613 tube. NOTE: Apply clean engine oil to O-ring seals. Fully insert the male tube end in the quick connect coupling and push the clip downward to lock the fuel tubes together. 3. Pull on the connection to make sure it is fully engaged. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Fuel Tank Pressure Transducer Sensor View 151-14 (Right Front) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Fuel Tank Pressure Transducer Sensor > Page 3618 View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Fuel Rail Pressure/Temperature Sensor C173 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Fuel Rail Pressure/Temperature Sensor > Page 3621 C435 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation > Fuel Rail Pressure (FRP) Sensor Fuel Pressure Sensor/Switch: Description and Operation Fuel Rail Pressure (FRP) Sensor FUEL RAIL PRESSURE (FRP) SENSOR Fuel Rail Pressure (FRP) Sensor The FRP sensor is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and the resistance decreases as the 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. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation > Fuel Rail Pressure (FRP) Sensor > Page 3624 Fuel Pressure Sensor/Switch: Description and Operation Fuel Rail Pressure Temperature (FRPT) Sensor FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR Typical Fuel Rail Pressure Temperature (FRPT) Sensor The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to determine the pressure difference between the fuel rail and the intake manifold. The relationship between fuel pressure and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. The temperature sensing portion of the FRPT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of the thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Both the pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation > Page 3625 Fuel Pressure Sensor/Switch: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE SENSOR Removal and Installation 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. Release the fuel system pressure. 2. Remove the intake manifold. 3. Disconnect the fuel rail pressure and temperature sensor vacuum and electrical connectors. 4. Remove the bolts and the fuel rail pressure and temperature sensor. - To install, tighten to 6 Nm (53 lb-in). 5. Remove and discard the O-ring seal. 6. CAUTION: Use an O-ring seal made of special fuel resistant material. Use of an ordinary O-ring seal can cause the fuel system to leak. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation > Page 3626 Do not reuse the O-ring seal. To install, reverse the removal procedure. Lubricate the new O-ring seal with clean engine oil. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Description and Operation Fuel Pressure Pulsation Damper: Description and Operation FUEL RAIL PULSE DAMPER Typical Fuel Rail Pulse Damper The fuel rail pulse damper is located on the fuel rail and reduces the 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 if the pulse damper diaphragm ruptures. The fuel rail pulse damper should not be confused with a fuel pressure regulator; it does not regulate the fuel rail pressure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Item....................................................................................................................................................... ..............................................................Specification Fuel Pressure Key on, engine off................................................................................................................................. .............................................207-276 kPa (30-40 psi) Engine running................................................. ..................................................................................................................................207-276 kPa (30-40 psi) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control Unit > Component Information > Locations View 151-17 (Right Rear, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control Unit > Component Information > Locations > Page 3637 C4033 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control Unit > Component Information > Locations > Page 3638 Fuel Pump Control Unit: Service and Repair FUEL PUMP DRIVER MODULE (FPDM) Removal and Installation 1. Remove the RH rear quarter trim panel. 2. Disconnect the fuel pump driver module (FPDM) electrical connector. 3. Remove the bolts and the FPDM. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3642 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail Fuel Rail: Service and Repair Fuel Rail FUEL RAIL Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail > Page 3647 Part 2 Exploded View Removal and Installation WARNING: - Do not smoke or carry lighted 6. 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 7. 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: If used as a leverage device, the fuel rail may be damaged. Care must be taken when working around the fuel rail. NOTE: During the repair or replacement of fuel-related components, cap, tape or otherwise appropriately protect all liquid and vapor fuel openings to prevent the ingress of dirt or other contamination. Remove all caps, tape and other protective materials prior to installation. 1. Disconnect the spring lock coupling. 2. Remove the intake manifold. 3. Remove the fuel supply tube bracket bolt. - To install, tighten to 8 Nm (71 lb-in). 4. Disconnect the fuel injector electrical connectors. 5. Disconnect the fuel pressure and temperature sensor electrical and vacuum connectors. 6. Remove the bolts and the fuel rail and injectors as an assembly. - To install, tighten to 23 Nm (17 lb-ft). 7. CAUTION: O-ring seals 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: Install new fuel injector-to-intake manifold O-ring seals and lubricate them with clean engine oil. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail > Page 3648 Fuel Rail: Service and Repair Fuel Rail Supply Tube FUEL RAIL SUPPLY TUBE Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail > Page 3649 Part 2 Exploded View Removal and Installation 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 can be ignited. Failure to follow these instructions can 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 can result in personal injury. NOTE: During the repair or replacement of fuel-related components, cap, tape or otherwise appropriately protect all liquid and vapor fuel openings to prevent the ingress of dirt or other contamination. Remove all caps, tape and other protective materials prior to installation. 1. Release the fuel system pressure. 2. Remove the intake manifold. 3. Disconnect the fuel rail supply tube spring lock coupling. 4. Remove the fuel rail supply tube bracket bolt. - To install, tighten to 8 Nm (71 lb-in). 5. Remove the 4 bolts and the fuel rail supply tube. - To install, tighten to 6 Nm (53 lb-in). 6. CAUTION: Use O-ring seals that are made of special fuel-resistant material. The use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse the O-ring seals. Remove and discard the fuel rail supply tube O-ring seals. 7. To install, reverse the removal procedure. - Lubricate the new O-ring seals with clean engine oil prior to installation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair Fuel Supply Line: Service and Repair FUEL LINES Explorer Sport Trac (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Page 3653 Explorer Sport Trac (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Page 3654 Explorer/Mountaineer (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Page 3655 Explorer/Mountaineer (Part 2) Exploded View Removal and Installation 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 can 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 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, which can cause a fire hazard. Failure to follow these instructions may result in personal injury. CAUTION: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or tubes. NOTE: During the repair or replacement of fuel-related components, all liquid and vapor fuel openings shall be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials shall be removed prior to installation. 1. With the vehicle in NEUTRAL, position it on hoist. 2. Release the fuel system pressure. 3. Disconnect the battery ground cable. 4. Disconnect the spring lock coupling at the engine and the vapor tube quick connect coupling at the purge valve. 5. Disconnect the quick connect coupling at the fuel filter and the vapor tube quick connect coupling at the fuel tank. 6. Remove the transmission. 7. Remove the fuel lines from the vehicle. 8. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair Fuel Filler Hose: Service and Repair FUEL TANK FILLER PIPE Explorer Sport Trac (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Page 3660 Explorer Sport Trac (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Page 3661 Explorer/Mountaineer (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Page 3662 Explorer/Mountaineer (Part 2) All Vehicles (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Page 3663 All Vehicles (Part 2) Exploded View Removal and Installation All vehicles 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. NOTE: During the repair or replacement of fuel-related components, all liquid and vapor fuel openings shall be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials shall be removed prior to installation. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Open the fuel tank filler cap. 4. Remove the 3 bolts and the fuel tank filler cap. - To install, tighten to 1 Nm (9 lb-in). Explorer/Mountaineer 5. NOTE: Body panel and fuel door removed for clarity. Depress the 2 tabs on the fresh air vent tube in the fuel filler door pocket and disconnect the fresh air vent tube from the inner fenderwell. All vehicles 6. Disconnect the fuel filler pipe vapor tube-to-fuel pressure sensor and vapor tube assembly quick connect coupling. 7. Disconnect the rear axle vent hose. 8. Disconnect the dust separator hose. 9. Loosen the fuel tank filler pipe hose clamp and disconnect the hose. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Page 3664 - To install, tighten to 3 Nm (27 lb-in). 10. Remove the 2 bolts and the fuel tank filler pipe assembly. - To install, tighten to 15 Nm (11 lb-ft). 11. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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: > 07-25-3 > Dec > 07 > Fuel System - Early Fuel Nozzle Shut-Off/DTC P0451 Fuel Filler Neck: Customer Interest Fuel System - Early Fuel Nozzle Shut-Off/DTC P0451 TSB 07-25-3 12/24/07 FUEL FILL - SLOW OR EARLY SHUT OFF - BUILT BEFORE 11/28/2007 FORD: 2006-2008 Explorer MERCURY: 2006-2008 Mountaineer ISSUE Some 2006-2008 Explorer and Mountaineer vehicles built before 11/28/2007 may exhibit a slow or difficult fuel fill or early pump shut off condition when refueling. This symptom may be accompanied by DTC P0451. This concern may be due to water or ice causing a restriction in the fresh air hose connected to the fuel filler housing and not allowing the fuel system to vent properly. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Replace the fuel filler pipe fresh air vent tube with the redesigned shepherd hook tube. Inspect the vapor lines and Evaporative Emissions (EVAP) canister for water contamination. If the vapor line has water in it, clean the lines with shop air. If EVAP canister is contaminated with water, replace the canister. 1. Disconnect the fresh air tube at the dust separator and inspect for water intrusion. a. If water is not present do not continue with this TSB. Follow normal diagnostic procedures found in the Work Shop Manual (WSM) Section 310-00 pinpoint test A. b. If water is present, replace the fuel filler pipe fresh air vent line with the revised vent line. 2. Remove the EVAP canister and inspect for water intrusion. If contaminated replace the EVAP canister. Refer to the WSM, Section 310-01. 3. Clean the vapor lines with 100 psi of regulated shop air. 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 072503A 2006-2008 2.4 Hrs. Explorer/Mountaineer: Replace The Fuel Filler Pipe Fresh Air Vent Line, And Evap Canister If Contaminated (Do Not Use With 9653A) DEALER CODING CONDITION BASIC PART NO. CODE 9S327 17 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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: > 07-25-3 > Dec > 07 > Fuel System - Early Fuel Nozzle Shut-Off/DTC P0451 > Page 3673 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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: > 07-25-3 > Dec > 07 > Fuel System - Early Fuel Nozzle Shut-Off/DTC P0451 Fuel Filler Neck: All Technical Service Bulletins Fuel System - Early Fuel Nozzle Shut-Off/DTC P0451 TSB 07-25-3 12/24/07 FUEL FILL - SLOW OR EARLY SHUT OFF - BUILT BEFORE 11/28/2007 FORD: 2006-2008 Explorer MERCURY: 2006-2008 Mountaineer ISSUE Some 2006-2008 Explorer and Mountaineer vehicles built before 11/28/2007 may exhibit a slow or difficult fuel fill or early pump shut off condition when refueling. This symptom may be accompanied by DTC P0451. This concern may be due to water or ice causing a restriction in the fresh air hose connected to the fuel filler housing and not allowing the fuel system to vent properly. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Replace the fuel filler pipe fresh air vent tube with the redesigned shepherd hook tube. Inspect the vapor lines and Evaporative Emissions (EVAP) canister for water contamination. If the vapor line has water in it, clean the lines with shop air. If EVAP canister is contaminated with water, replace the canister. 1. Disconnect the fresh air tube at the dust separator and inspect for water intrusion. a. If water is not present do not continue with this TSB. Follow normal diagnostic procedures found in the Work Shop Manual (WSM) Section 310-00 pinpoint test A. b. If water is present, replace the fuel filler pipe fresh air vent line with the revised vent line. 2. Remove the EVAP canister and inspect for water intrusion. If contaminated replace the EVAP canister. Refer to the WSM, Section 310-01. 3. Clean the vapor lines with 100 psi of regulated shop air. 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 072503A 2006-2008 2.4 Hrs. Explorer/Mountaineer: Replace The Fuel Filler Pipe Fresh Air Vent Line, And Evap Canister If Contaminated (Do Not Use With 9653A) DEALER CODING CONDITION BASIC PART NO. CODE 9S327 17 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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: > 07-25-3 > Dec > 07 > Fuel System - Early Fuel Nozzle Shut-Off/DTC P0451 > Page 3679 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 Fuel Gauge Sender: Customer Interest Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 TSB 06-17-10 09/04/06 MIL ON WITH DTC P0463 OR ERRATIC FUEL GAUGE OPERATION FORD: 2004-2007 Explorer MERCURY: 2004-2007 Mountaineer This article supersedes TSB 06-16-7 to update the Service Procedure. ISSUE Some 2004-2007 Explorer 4dr/Mountaineer vehicles may exhibit the malfunction indicator lamp (MIL) on with diagnostic trouble code (DTC) P0463 or an erratic fuel gauge concern. This could be from sulphur contamination in the fuel, causing an open or high resistance on the fuel sender card. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. For vehicles with customer symptom of erratic fuel gauge operation (with no MIL on), proceed to Step 1a. For vehicles with a customer symptom including the MIL on, proceed to Step 1b. If unable to verify the concern, do not continue with this TSB. a. Follow the appropriate pinpoint test (PPT) for "Fuel Gauge Inaccurate" in Workshop Manual (WSM), Section 413-01. If PPT test results lead to fuel pump module replacement, proceed to Step 2. If PPT test results isolate any problem other than fuel pump module replacement, repair as indicated and do not continue with this TSB. b. Install diagnostic scan tool to retrieve DTCs. If DTC P0463 is retrieved, proceed to Step 2. If DTC P0463 is not retrieved, this TSB does not apply, follow normal WSM diagnostics. 2. Remove fuel tank per WSM, Section 310-01. 3. Remove fuel pump assembly from fuel tank per WSM, Section 310-01. See Figure 1 (Chart) to determine if a kit (contains a fuel level sensor assembly, a wire harness and heat shrink tube) or fuel pump assembly is required for repair. For vehicles that can be serviced with a kit go to Step 4. For vehicles that require fuel pump assembly replacement, go to Step 12. 4. Remove the fuel level sensor assembly (sender card/float rod assembly) from the fuel pump assembly per WSM, Section 310-01. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 3688 5. Detach electrical connector from fuel pump housing (Figure 2). 6. Remove wiring harness from the fuel pump assembly flange by depressing the retaining fingers on the harness connector at bottom of flange and pushing upward out of flange (Figure 3). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 3689 7. Install new wiring harness by feeding wires through flange hole and inserting harness connector into flange until an audible click is heard. Check for proper retention. 8. Re-attach electrical connector harness to fuel pump housing. Prior to making the connection place one loop in the pump wires away from the convoluted feed tube (Figure 4). 9. Re-attach the signal wire (yellow) on the harness to the signal wire (yellow) on the replacement fuel level sensor assembly per WSM, Section 310-01 (Figure 5). 10. Wrap the ground wire one time around the signal wire and attach the ground wire terminal to the terminal on the fuel level sensor assembly. Check for proper retention. NOTE THE GROUND WIRE MUST BE WRAPPED AROUND THE SIGNAL WIRE, AS DESCRIBED IN STEP 10, TO PREVENT POTENTIAL INTERFERENCE WITH THE FLOAT ROD ARM. 11. Re-attach the fuel level sensor assembly to the fuel pump housing, making sure that both the signal wire and the ground wire are routed through the Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 3690 gap between the fuel level sensor assembly and fuel pump bracket. Torque the fastener at the bottom of the fuel level sensor assembly to 1 N.m (9 lb-in). 12. Re-install fuel pump assembly into fuel tank per WSM, Section 310-01. NOTE TAKE CARE NOT TO DAMAGE/BEND FLOAT ROD OR SENDER CARD DURING INSTALLATION OF FUEL PUMP ASSEMBLY. 13. Re-install fuel tank per WSM, Section 310-01. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 061710A 2004-2007 2.9 Hrs. Explorer/Mountaineer: Diagnose And Replace The Fuel Gauge Tank Unit (Do Not Use With 9275D, 9275A, 9002A) DEALER CODING CONDITION BASIC PART NO. CODE 9A299 28 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 Fuel Gauge Sender: All Technical Service Bulletins Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 TSB 06-17-10 09/04/06 MIL ON WITH DTC P0463 OR ERRATIC FUEL GAUGE OPERATION FORD: 2004-2007 Explorer MERCURY: 2004-2007 Mountaineer This article supersedes TSB 06-16-7 to update the Service Procedure. ISSUE Some 2004-2007 Explorer 4dr/Mountaineer vehicles may exhibit the malfunction indicator lamp (MIL) on with diagnostic trouble code (DTC) P0463 or an erratic fuel gauge concern. This could be from sulphur contamination in the fuel, causing an open or high resistance on the fuel sender card. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. For vehicles with customer symptom of erratic fuel gauge operation (with no MIL on), proceed to Step 1a. For vehicles with a customer symptom including the MIL on, proceed to Step 1b. If unable to verify the concern, do not continue with this TSB. a. Follow the appropriate pinpoint test (PPT) for "Fuel Gauge Inaccurate" in Workshop Manual (WSM), Section 413-01. If PPT test results lead to fuel pump module replacement, proceed to Step 2. If PPT test results isolate any problem other than fuel pump module replacement, repair as indicated and do not continue with this TSB. b. Install diagnostic scan tool to retrieve DTCs. If DTC P0463 is retrieved, proceed to Step 2. If DTC P0463 is not retrieved, this TSB does not apply, follow normal WSM diagnostics. 2. Remove fuel tank per WSM, Section 310-01. 3. Remove fuel pump assembly from fuel tank per WSM, Section 310-01. See Figure 1 (Chart) to determine if a kit (contains a fuel level sensor assembly, a wire harness and heat shrink tube) or fuel pump assembly is required for repair. For vehicles that can be serviced with a kit go to Step 4. For vehicles that require fuel pump assembly replacement, go to Step 12. 4. Remove the fuel level sensor assembly (sender card/float rod assembly) from the fuel pump assembly per WSM, Section 310-01. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 3696 5. Detach electrical connector from fuel pump housing (Figure 2). 6. Remove wiring harness from the fuel pump assembly flange by depressing the retaining fingers on the harness connector at bottom of flange and pushing upward out of flange (Figure 3). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 3697 7. Install new wiring harness by feeding wires through flange hole and inserting harness connector into flange until an audible click is heard. Check for proper retention. 8. Re-attach electrical connector harness to fuel pump housing. Prior to making the connection place one loop in the pump wires away from the convoluted feed tube (Figure 4). 9. Re-attach the signal wire (yellow) on the harness to the signal wire (yellow) on the replacement fuel level sensor assembly per WSM, Section 310-01 (Figure 5). 10. Wrap the ground wire one time around the signal wire and attach the ground wire terminal to the terminal on the fuel level sensor assembly. Check for proper retention. NOTE THE GROUND WIRE MUST BE WRAPPED AROUND THE SIGNAL WIRE, AS DESCRIBED IN STEP 10, TO PREVENT POTENTIAL INTERFERENCE WITH THE FLOAT ROD ARM. 11. Re-attach the fuel level sensor assembly to the fuel pump housing, making sure that both the signal wire and the ground wire are routed through the Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 3698 gap between the fuel level sensor assembly and fuel pump bracket. Torque the fastener at the bottom of the fuel level sensor assembly to 1 N.m (9 lb-in). 12. Re-install fuel pump assembly into fuel tank per WSM, Section 310-01. NOTE TAKE CARE NOT TO DAMAGE/BEND FLOAT ROD OR SENDER CARD DURING INSTALLATION OF FUEL PUMP ASSEMBLY. 13. Re-install fuel tank per WSM, Section 310-01. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 061710A 2004-2007 2.9 Hrs. Explorer/Mountaineer: Diagnose And Replace The Fuel Gauge Tank Unit (Do Not Use With 9275D, 9275A, 9002A) DEALER CODING CONDITION BASIC PART NO. CODE 9A299 28 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 3699 Fuel Gauge Sender: Description and Operation FUEL PUMP (FP) MODULE Typical Electronic Returnless Fuel Pump (FP) Module Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 3700 Typical Mechanical Returnless Fuel Pump (FP) Module The FP module 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. FUEL PUMP (FP) MODULE AND RESERVOIR The FP module is mounted inside the fuel tank in a reservoir. The pump has a discharge check valve that maintains the system pressure after the key has been turned off to minimize starting concerns. The reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low tank fill levels. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 3701 Fuel Gauge Sender: Service and Repair FUEL LEVEL SENSOR Explorer Sport Trac (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 3702 Explorer Sport Trac (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 3703 Explorer/Mountaineer (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 3704 Explorer/Mountaineer (Part 2) All Vehicles (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 3705 All Vehicles (Part 2) Removal 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. 1. Remove the fuel pump. 2. NOTE: Note the routing of the sending unit wire for installation. Remove the heat shrink tube covering the electrical connector. 3. Disconnect the electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 3706 4. Remove the screw and lift up to remove the fuel gauge sending unit. Installation 1. Route the fuel gauge sending unit wire through the center of the fuel pump module. 2. NOTE: - Both fuel gauge sending wires must be routed behind the metal sending unit plate. - The grounding eyelet must be on the front side of the sending unit. Hook the fuel gauge sending unit on the fuel pump module and install the screw through the grounding eyelet and tighten the screw. 3. Slide the heat shrink tube onto the wire harness and connect the electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 3707 4. WARNING: Do not use an open flame to shrink the heat shrink tube, use a heat gun only. Failure to follow these instructions may result in personal injury. Using a heat gun, shrink the heat shrink tube. 5. Install the fuel pump. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Service and Repair Fuel Tank Mounting Straps: Service and Repair FUEL TANK SUPPORT STRAPS Explorer Sport Trac (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Service and Repair > Page 3711 Explorer Sport Trac (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Service and Repair > Page 3712 Explorer/Mountaineer (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Service and Repair > Page 3713 Explorer/Mountaineer (Part 2) All Vehicles (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Service and Repair > Page 3714 All Vehicles (Part 2) Exploded View Removal and Installation WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury. All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If equipped, remove the 4 bolts, the nut and the fuel tank skid plate. - To install, tighten to 40 Nm (30 lb-ft). Explorer/Mountaineer 3. Remove the driveshaft. All vehicles 4. Using a suitable jack, support the fuel tank. 5. Remove the bolt and the fuel tank rear support strap. - To install, tighten to 48 Nm (35 lb-ft). 6. Remove the nut and the fuel tank front support strap. - To install, tighten to 48 Nm (35 lb-ft). 7. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Description and Operation Fuel Tank Unit: Description and Operation FUEL PUMP (FP) MODULE Typical Electronic Returnless Fuel Pump (FP) Module Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Description and Operation > Page 3718 Typical Mechanical Returnless Fuel Pump (FP) Module The FP module 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. FUEL PUMP (FP) MODULE AND RESERVOIR The FP module is mounted inside the fuel tank in a reservoir. The pump has a discharge check valve that maintains the system pressure after the key has been turned off to minimize starting concerns. The reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low tank fill levels. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3722 C173 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3723 Fuel Temperature Sensor: Description and Operation FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR Typical Fuel Rail Pressure Temperature (FRPT) Sensor The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to determine the pressure difference between the fuel rail and the intake manifold. The relationship between fuel pressure and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. The temperature sensing portion of the FRPT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of the thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Both the pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3724 Fuel Temperature Sensor: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE SENSOR Removal and Installation 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. Release the fuel system pressure. 2. Remove the intake manifold. 3. Disconnect the fuel rail pressure and temperature sensor vacuum and electrical connectors. 4. Remove the bolts and the fuel rail pressure and temperature sensor. - To install, tighten to 6 Nm (53 lb-in). 5. Remove and discard the O-ring seal. 6. CAUTION: Use an O-ring seal made of special fuel resistant material. Use of an ordinary O-ring seal can cause the fuel system to leak. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3725 Do not reuse the O-ring seal. To install, reverse the removal procedure. Lubricate the new O-ring seal with clean engine oil. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation Idle Speed/Throttle Actuator - Electronic: Description and Operation IDLE AIR CONTROL (IAC) VALVE NOTE: The IAC valve assembly is not adjustable and cannot be cleaned, also some IAC valves are normally open and others are normally closed. Some IAC valves require engine vacuum to operate. The IAC valve assembly controls the 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. 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 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations View 151-11 (behind Dash Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3732 C282 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3733 Inertia Fuel Shutoff Switch: Description and Operation INERTIA FUEL SHUTOFF (IFS) SWITCH Typical Inertia Fuel Shutoff (IFS) Switch The IFS switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shutoff 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's Literature for the location of the IFS. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3734 Inertia Fuel Shutoff Switch: Service and Repair INERTIA FUEL SHUTOFF (IFS) SWITCH Removal and Installation 1. NOTE: The front passenger door frame scuff plate is retained only by internal metal clips. Remove the front passenger door frame scuff plate. 2. NOTE: - The front passenger door side interior kick panel is retained only by internal metal clips. - It may be necessary to reposition the lower end of the door jam weather stripping to remove the front passenger door side interior kick panel. Remove the front passenger side interior kick panel. 3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Remove the bolts and the IFS switch - To install, tighten to 2 Nm (18 lb-in). 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Service and Repair Intake Air Duct: Service and Repair AIR CLEANER OUTLET PIPE Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Service and Repair > Page 3738 Exploded View Removal and Installation Vehicles equipped with a 4.0L SOHC engine 1. Detach the wiring harness retainer from the air cleaner outlet pipe. Vehicles equipped with a 4.6L (3V) engine 2. Disconnect the brake booster vacuum hose from the air cleaner outlet pipe. All vehicles 3. Disconnect the crankcase breather hose from the air cleaner outlet pipe. 4. Loosen the clamps and remove the air cleaner outlet pipe. 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3742 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations View 151-17 (Right Rear, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 3747 C4033 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 3748 Fuel Pump Control Unit: Service and Repair FUEL PUMP DRIVER MODULE (FPDM) Removal and Installation 1. Remove the RH rear quarter trim panel. 2. Disconnect the fuel pump driver module (FPDM) electrical connector. 3. Remove the bolts and the FPDM. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3752 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3756 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations View 151-11 (behind Dash Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3761 C2040 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3762 Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR The APP sensor is an input to the powertrain control module (PCM) and is used to determine the torque demand. There are 3 pedal position signals in the sensor. Signal 1, APPS1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, APPS2 and APPS3, both have a positive slope (increasing angle, increasing voltage). During normal operation APPS1 is used as the indication of pedal position by the strategy. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern. There are 2 reference voltage circuits and 2 signal return circuits for the sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3766 C128 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3767 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW (MAF) SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT Sensor Wire Where Applicable) Terminals Typical Mass Air Flow (MAF) Sensor Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3768 Typical Drop-in Mass Air Flow (MAF) Sensor The 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 the ambient temperature as measured by a constant cold wire. The current required to maintain the temperature of the hot wire is proportional to the mass air 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. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Most MAF sensors have integrated bypass technology with an integrated intake air temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3769 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Disconnect the mass air flow (MAF) sensor electrical connector. 2. Remove the bolts and the MAF. - To install, tighten to 2 Nm (18 lb-in). 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Fuel Tank Pressure Transducer Sensor View 151-14 (Right Front) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Fuel Tank Pressure Transducer Sensor > Page 3774 View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Fuel Rail Pressure/Temperature Sensor C173 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Fuel Rail Pressure/Temperature Sensor > Page 3777 C435 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Rail Pressure (FRP) Sensor Fuel Pressure Sensor/Switch: Description and Operation Fuel Rail Pressure (FRP) Sensor FUEL RAIL PRESSURE (FRP) SENSOR Fuel Rail Pressure (FRP) Sensor The FRP sensor is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and the resistance decreases as the 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. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Rail Pressure (FRP) Sensor > Page 3780 Fuel Pressure Sensor/Switch: Description and Operation Fuel Rail Pressure Temperature (FRPT) Sensor FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR Typical Fuel Rail Pressure Temperature (FRPT) Sensor The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to determine the pressure difference between the fuel rail and the intake manifold. The relationship between fuel pressure and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. The temperature sensing portion of the FRPT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of the thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Both the pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves 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 (V6-4.0L VIN K (2007)) 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 > Page 3781 Fuel Pressure Sensor/Switch: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE SENSOR Removal and Installation 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. Release the fuel system pressure. 2. Remove the intake manifold. 3. Disconnect the fuel rail pressure and temperature sensor vacuum and electrical connectors. 4. Remove the bolts and the fuel rail pressure and temperature sensor. - To install, tighten to 6 Nm (53 lb-in). 5. Remove and discard the O-ring seal. 6. CAUTION: Use an O-ring seal made of special fuel resistant material. Use of an ordinary O-ring seal can cause the fuel system to leak. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Page 3782 Do not reuse the O-ring seal. To install, reverse the removal procedure. Lubricate the new O-ring seal with clean engine oil. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3786 C173 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3787 Fuel Temperature Sensor: Description and Operation FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR Typical Fuel Rail Pressure Temperature (FRPT) Sensor The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to determine the pressure difference between the fuel rail and the intake manifold. The relationship between fuel pressure and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. The temperature sensing portion of the FRPT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of the thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance changes the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Both the pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3788 Fuel Temperature Sensor: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE SENSOR Removal and Installation 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. Release the fuel system pressure. 2. Remove the intake manifold. 3. Disconnect the fuel rail pressure and temperature sensor vacuum and electrical connectors. 4. Remove the bolts and the fuel rail pressure and temperature sensor. - To install, tighten to 6 Nm (53 lb-in). 5. Remove and discard the O-ring seal. 6. CAUTION: Use an O-ring seal made of special fuel resistant material. Use of an ordinary O-ring seal can cause the fuel system to leak. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3789 Do not reuse the O-ring seal. To install, reverse the removal procedure. Lubricate the new O-ring seal with clean engine oil. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 View 151-11 (behind Dash Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3793 C282 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3794 Inertia Fuel Shutoff Switch: Description and Operation INERTIA FUEL SHUTOFF (IFS) SWITCH Typical Inertia Fuel Shutoff (IFS) Switch The IFS switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shutoff 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's Literature for the location of the IFS. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3795 Inertia Fuel Shutoff Switch: Service and Repair INERTIA FUEL SHUTOFF (IFS) SWITCH Removal and Installation 1. NOTE: The front passenger door frame scuff plate is retained only by internal metal clips. Remove the front passenger door frame scuff plate. 2. NOTE: - The front passenger door side interior kick panel is retained only by internal metal clips. - It may be necessary to reposition the lower end of the door jam weather stripping to remove the front passenger door side interior kick panel. Remove the front passenger side interior kick panel. 3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Remove the bolts and the IFS switch - To install, tighten to 2 Nm (18 lb-in). 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3799 C189 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Electronic Throttle Body (ETB) Position Sensor Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR The ETB position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB position signals are required for increased monitoring. The first ETB position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). During normal operation the negative slope ETB position sensor signal (TP1) is used by the control strategy as the indication of throttle position. The 2 ETB position sensor signals make sure the PCM receives a correct input even if 1 signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Electronic Throttle Body (ETB) Position Sensor > Page 3802 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor THROTTLE POSITION (TP) SENSOR Typical TP Sensor The TP sensor 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 3-blade electrical connector that may be gold plated. The gold plating increases the corrosion resistance on the terminals and increases the connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM from the TP. The operating 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) - throttle angle rate Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3803 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Removal Vehicles equipped with a 4.6L (3V) engine 1. Remove the air cleaner outlet pipe. 2. Remove the bolts and position the heated positive crankcase ventilation (PCV) fitting and hoses aside. - Remove and discard the O-ring seal. All vehicles 3. Disconnect the throttle position (TP) sensor electrical connector. 4. CAUTION: Failure to remove the TP sensor screws in the following manner will result in damage to the screws. First loosen the screws 1-2 full turns using a hand tool and then use a suitable high-speed driver to complete the removal. Remove and discard the 2 screws and the TP sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3804 Installation All vehicles 1. CAUTION: - Do not reuse the TP sensor and screws. A new TP sensor and screws must be installed. - Do not use a high-speed driver to install the new screws or damage to the TP sensor can occur. NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor is aligned with the radial locator hole on the throttle body. Position the new TP sensor and install the 2 new screws. Tighten to 3 Nm (27 lb-in). 2. Connect the TP sensor electrical connector. Vehicles equipped with a 4.6L (3V) engine 3. Install a new O-ring seal, position the heated PCV fitting and install the bolts. 4. Install the air cleaner outlet pipe. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair Throttle Body: Service and Repair THROTTLE BODY Removal and Installation 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: The throttle body must be removed from the vehicle to be cleaned. Do not hold the throttle plate open with any object that could scratch the bore or plate while servicing or cleaning the throttle body. 1. Remove the air cleaner outlet tube. 2. Disconnect the electronic throttle body (TB) electrical connector. 3. Disconnect the throttle position (TP) sensor electrical connector. 4. Remove the nut and position the wiring harness bracket aside. 5. Remove the bolts, the electronic TB and the gasket. Discard the gasket. - To install, tighten to 9 Nm (80 lb-in). 6. To install, reverse the removal procedure. - Install a new electronic TB gasket. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3811 C189 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Electronic Throttle Body (ETB) Position Sensor Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR The ETB position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB position signals are required for increased monitoring. The first ETB position sensor signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). During normal operation the negative slope ETB position sensor signal (TP1) is used by the control strategy as the indication of throttle position. The 2 ETB position sensor signals make sure the PCM receives a correct input even if 1 signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Electronic Throttle Body (ETB) Position Sensor > Page 3814 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor THROTTLE POSITION (TP) SENSOR Typical TP Sensor The TP sensor 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 3-blade electrical connector that may be gold plated. The gold plating increases the corrosion resistance on the terminals and increases the connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM from the TP. The operating 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) - throttle angle rate Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 3815 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Removal Vehicles equipped with a 4.6L (3V) engine 1. Remove the air cleaner outlet pipe. 2. Remove the bolts and position the heated positive crankcase ventilation (PCV) fitting and hoses aside. - Remove and discard the O-ring seal. All vehicles 3. Disconnect the throttle position (TP) sensor electrical connector. 4. CAUTION: Failure to remove the TP sensor screws in the following manner will result in damage to the screws. First loosen the screws 1-2 full turns using a hand tool and then use a suitable high-speed driver to complete the removal. Remove and discard the 2 screws and the TP sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 3816 Installation All vehicles 1. CAUTION: - Do not reuse the TP sensor and screws. A new TP sensor and screws must be installed. - Do not use a high-speed driver to install the new screws or damage to the TP sensor can occur. NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor is aligned with the radial locator hole on the throttle body. Position the new TP sensor and install the 2 new screws. Tighten to 3 Nm (27 lb-in). 2. Connect the TP sensor electrical connector. Vehicles equipped with a 4.6L (3V) engine 3. Install a new O-ring seal, position the heated PCV fitting and install the bolts. 4. Install the air cleaner outlet pipe. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Actuator > Component Information > Diagrams C1442 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Actuator > Component Information > Diagrams > Page 3821 Variable Induction Control Actuator: Description and Operation INTAKE MANIFOLD TUNING VALVE (IMTV) WARNING: Substantial opening and closing torque is applied by this system. To prevent injury, be careful to keep fingers away from lever mechanisms when actuated. The IMTV 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 is not energized below approximately 2,600 RPM. The shutter is in the closed position not allowing airflow blend to occur in the intake manifold. The motorized unit is energized above approximately 2,600 RPM. The motorized unit is 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. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications Item....................................................................................................................................................... ..............................................................Specification Firing order........................................................................................................................................... ..................................................................1-4-2-5-3-6 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > System Information > Specifications Ignition Timing: Specifications Item....................................................................................................................................................... ..............................................................Specification Base ignition timing.............................................................................................................................. ..............................10 degrees BTDC Non-adjustable Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor C180 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 3834 C1366 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 3835 C1367 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3836 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR Typical Synchronizer Hall-Effect CMP Sensor Typical Variable Reluctance CMP Sensor The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to select the correct ignition coil to fire. Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor and the 2-pin connector variable reluctance type sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3837 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation 1. Disconnect the camshaft position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. - To install, tighten to 6 Nm (53 lb-in). 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3841 Crankshaft Position Sensor: Diagrams C101 C1120 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3842 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Typical Crankshaft Position (CKP) Sensor The 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 PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L 10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor 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 a fixed reference for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid deceleration between teeth. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3843 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). 4. NOTE: Be sure the sensor wiring is routed away from the battery cable. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service and Repair Ignition Cable: Service and Repair SPARK PLUG WIRES Exploded View Special Tool(s) Special Tool(s) Removal and Installation 1. CAUTION: It is important to twist the spark plug wire boot while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service and Repair > Page 3847 Squeeze the locking tabs and twist while pulling upward to disconnect the 6 spark plug wires from the ignition coil. 2. Detach the spark plug wires from the spark plug wire retainers. 3. CAUTION: It is important to twist the spark plug wire boot while pulling upward to avoid damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct spark plug. With a twisting motion, use the special tool to pull the spark plug wires from the spark plugs. 4. NOTE: Apply silicone dielectric compound to the inside of the spark plug wire boots. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications Torque Specifications Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Ignition Coil C1065 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Ignition Coil > Page 3853 C1196 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Ignition Coil > Page 3854 C174 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Ignition Coil > Page 3855 C194 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 3856 Ignition Coil: Description and Operation COIL ON PLUG (COP) Typical Coil On Plug (COP) The COP ignition operates similar to a standard coil pack ignition except each plug has one coil per plug. The COP has 3 different modes of operation: engine crank, engine running, and CMP failure mode effects management (FMEM). COIL PACK Typical Four-Tower Coil Pack Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 3857 Typical Six-Tower Coil Pack The PCM provides a grounding switch for the coil primary circuit. When the switch is closed, voltage is applied to the coil primary circuit. This creates a magnetic field around the primary coil. The PCM opens the switch, causing the magnetic field to collapse, inducing the high voltage in the secondary coil windings and firing the spark plug. The spark plugs are paired so that as one spark plug fires on the compression stroke, the other spark plug fires on the exhaust stroke. The next time the coil is fired the order is reversed. The next pair of spark plugs fire according to the engine firing order. Coil packs come in 4-tower, 6-tower horizontal and series 5 6-tower models. Two adjacent coil towers share a common coil and are called a matched pair. For 6-tower coil pack (6 cylinder) applications, the matched pairs are 1 and 5, 2 and 6, and 3 and 4. For 4-tower coil pack (4 cylinder) applications, the matched pairs are 1 and 4, and 2 and 3. 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 3858 Ignition Coil: Service and Repair IGNITION COIL Exploded View Removal and Installation 1. Disconnect the ignition coil electrical connector. 2. Disconnect the radio noise suppressor electrical connector. 3. NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Squeeze the tabs and twist, while pulling upward to disconnect the 6 spark plug wires from the ignition coil. 4. Remove the 4 bolts and the ignition coil. - To install, tighten to 6 Nm (53 lb-in). 5. NOTE: Apply silicone dielectric compound to the inside of the ignition coil boots. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Locations > Page 3862 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3866 C108 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3867 Knock Sensor: Description and Operation KNOCK SENSOR (KS) Two Types Of Knock Sensor (KS) The KS 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3868 Knock Sensor: Service and Repair KNOCK SENSOR (KS) Removal and Installation 1. Remove the intake manifold. 2. Disconnect the knock sensor (KS) electrical connector. 3. Remove the bolt and the KS. - To install, tighten to 20 Nm (15 lb-ft). 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 3873 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor C180 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 3880 C1366 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 3881 C1367 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3882 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR Typical Synchronizer Hall-Effect CMP Sensor Typical Variable Reluctance CMP Sensor The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to select the correct ignition coil to fire. Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor and the 2-pin connector variable reluctance type sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3883 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation 1. Disconnect the camshaft position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. - To install, tighten to 6 Nm (53 lb-in). 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3887 Crankshaft Position Sensor: Diagrams C101 C1120 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3888 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Typical Crankshaft Position (CKP) Sensor The 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 PCM. The pulse wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L 10-cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP sensor 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 a fixed reference for the CKP sensor configuration. The PCM also uses the CKP signal to determine if a misfire has occurred by measuring rapid deceleration between teeth. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3889 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the crankshaft position (CKP) sensor electrical connector. 3. Remove the bolt and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). 4. NOTE: Be sure the sensor wiring is routed away from the battery cable. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER Removal and Installation NOTE: - When any new lock cylinder is installed, the driver door and ignition lock cylinders should be installed as a set. This eliminates carrying an extra key which fits only 1 lock. If a new key is used, 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. With the ignition switch in the ON position, press the locking pin with a suitable tool and remove the ignition lock cylinder. 2. To install, reverse the removal procedure. - Lubricate the ignition lock cylinder during installation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3897 C108 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3898 Knock Sensor: Description and Operation KNOCK SENSOR (KS) Two Types Of Knock Sensor (KS) The KS 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3899 Knock Sensor: Service and Repair KNOCK SENSOR (KS) Removal and Installation 1. Remove the intake manifold. 2. Disconnect the knock sensor (KS) electrical connector. 3. Remove the bolt and the KS. - To install, tighten to 20 Nm (15 lb-ft). 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > General Specifications Spark Plug: Specifications General Specifications Item....................................................................................................................................................... ..............................................................Specification Spark plug gap..................................................................................................................................... ....................................1.32-1.42 mm (0.052-0.056 in) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > General Specifications > Page 3904 Torque Specifications Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3905 Spark Plug: Application and ID SPARK PLUG TYPE LH ........................................................................................................................................................ .......................................................... AGSF24PM RH ....................................................................................................................................................... ........................................................ AGSF24PGM Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3906 Spark Plug: Testing and Inspection Spark Plug Inspection 1. Inspect the spark plug for a bridged gap. ^ Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or carbon fouling. ^ Clean the spark plug. 2. Check for oil fouling. ^ Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil entering the combustion chamber through worn rings and pistons, excessive valve-to-guide clearance or worn or loose bearings. ^ Correct the oil leak concern. ^ Install a new spark plug. 3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips, exposed shell surfaces and electrodes, caused by a spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive idling. ^ Clean the spark plug. 4. Inspect for normal burning. ^ Check for light tan or gray deposits on the firing tip. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3907 5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator. Metallic deposits on the insulator indicate engine damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized installation of a heli-coil insert in place of the spark plug threads. ^ Install a new spark plug. 6. Inspect for overheating, identified by white or light gray spots and with bluish-burnt appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing. ^ Install a new spark plug. 7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. ^ Clean the spark plug. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3908 Spark Plug: Service and Repair SPARK PLUGS Exploded View Special Tool(s) Removal and Installation Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3909 1. CAUTION: It is important to twist the spark plug wire boot while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct spark plug. With a twisting motion, use the special tool to pull the spark plug wire from the spark plug. 2. NOTE: Use compressed air to remove any foreign material from the spark plug wells before removing the spark plugs Remove the spark plugs. To install, tighten to 17 Nm (13 lb-ft). 3. Use a suitable spark plug gap tool to check and adjust the spark plug gap. 4. NOTE: Apply silicone dielectric compound to the inside of the spark plug wire boots. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Specifications Pressure Regulating Solenoid: Specifications Solenoid Operation Chart Solenoid Operation Chart Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3918 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3919 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3920 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3921 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3922 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3923 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3924 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3925 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3926 Pressure Regulating Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3927 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3928 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3929 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3930 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3931 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3932 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3933 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3934 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3935 Pressure Regulating Solenoid: Testing and Inspection Pinpoint Tests - OSC Equipped Vehicle Special Tool(s) (Part 1) Special Tool(s) (Part 2) Shift Solenoid Pre-Diagnosis Any time an electrical connector or solenoid body is disconnected, inspect the connector for terminal condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install new as necessary. Use this shift solenoid operation information when carrying out Pinpoint Test A. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3936 Solenoid Operation Chart (Part 1) Solenoid Operation Chart (Part 2) Shift Solenoid Failure Mode Chart Failed ON or OFF due to powertrain control module (PCM) and/or vehicle wiring concerns, solenoid electrically, mechanically or hydraulically stuck ON or OFF. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3937 SSA, SSB SSC, SSD Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3938 PC A, PC B, PC C (Part 1) PC A, PC B, PC C (Part 2) PC A, PC B, PC C (Part 3) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3939 Pressure Regulating Solenoid: Service and Repair Solenoid Body Assembly Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the drain plug and drain the fluid. 3. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. Disconnect the solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the gasket should be reused. Remove the 16 transmission fluid pan screws, fluid pan and gasket. 5. Remove the transmission fluid filter. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3940 6. CAUTION: Do not damage the solenoid body connector pins. Remove the solenoid body bolts and remove the solenoid body by pulling down on the solenoid body and pushing down on the connector from the other side of the case. Installation 1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean automatic transmission fluid. 2. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur. Install the solenoid body. Tighten the bolts in sequence shown. ^ Tighten to 8 Nm (71 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3941 3. CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be damaged. NOTE: Make sure that the fluid filter seals are correctly seated on the filter. Lubricate the seals and install the transmission fluid filter. ^ Tighten to 10 Nm (89 inch lbs.) 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage, if not damaged, the gasket should be reused. Install the transmission fluid pan and gasket and loosely install the screws. 5. Tighten the screws in a crisscross sequence. ^ Tighten to 11 Nm (8 ft. lbs.) 6. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the specification. NOTE: Always install new O-ring seals on vehicle harness connector. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission connector and connect the connector. ^ Tighten to 5 Nm (44 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3942 7. Fill the transmission. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Brake Shift Interlock Actuator Removal 1. Remove the front floor console. For additional information, refer to Console. 2. Disconnect the brake shift lock actuator electrical connector. 3. Remove the screw and the brake shift lock actuator. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 3946 Installation 1. Install the brake shift lock actuator. 2. Connect the brake shift lock actuator electrical connector. 3. Install the front floor console. For additional information, refer to Console. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Specifications Shift Solenoid: Specifications Solenoid Operation Chart Solenoid Operation Chart Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3952 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3953 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3954 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3955 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3956 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3957 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3958 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3959 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3960 Shift Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3961 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3962 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3963 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3964 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3965 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3966 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3967 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3968 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3969 Shift Solenoid: Testing and Inspection Pinpoint Tests - OSC Equipped Vehicle Special Tool(s) (Part 1) Special Tool(s) (Part 2) Shift Solenoid Pre-Diagnosis Any time an electrical connector or solenoid body is disconnected, inspect the connector for terminal condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install new as necessary. Use this shift solenoid operation information when carrying out Pinpoint Test A. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3970 Solenoid Operation Chart (Part 1) Solenoid Operation Chart (Part 2) Shift Solenoid Failure Mode Chart Failed ON or OFF due to powertrain control module (PCM) and/or vehicle wiring concerns, solenoid electrically, mechanically or hydraulically stuck ON or OFF. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3971 SSA, SSB SSC, SSD Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3972 PC A, PC B, PC C (Part 1) PC A, PC B, PC C (Part 2) PC A, PC B, PC C (Part 3) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3973 Shift Solenoid: Service and Repair Solenoid Body Assembly Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the drain plug and drain the fluid. 3. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. Disconnect the solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the gasket should be reused. Remove the 16 transmission fluid pan screws, fluid pan and gasket. 5. Remove the transmission fluid filter. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3974 6. CAUTION: Do not damage the solenoid body connector pins. Remove the solenoid body bolts and remove the solenoid body by pulling down on the solenoid body and pushing down on the connector from the other side of the case. Installation 1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean automatic transmission fluid. 2. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur. Install the solenoid body. Tighten the bolts in sequence shown. ^ Tighten to 8 Nm (71 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3975 3. CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be damaged. NOTE: Make sure that the fluid filter seals are correctly seated on the filter. Lubricate the seals and install the transmission fluid filter. ^ Tighten to 10 Nm (89 inch lbs.) 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage, if not damaged, the gasket should be reused. Install the transmission fluid pan and gasket and loosely install the screws. 5. Tighten the screws in a crisscross sequence. ^ Tighten to 11 Nm (8 ft. lbs.) 6. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the specification. NOTE: Always install new O-ring seals on vehicle harness connector. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission connector and connect the connector. ^ Tighten to 5 Nm (44 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3976 7. Fill the transmission. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Solenoid Operation Chart Solenoid Operation Chart Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3982 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3983 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3984 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3985 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3986 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3987 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3988 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3989 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3990 Torque Converter Clutch Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3991 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3992 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3993 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3994 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3995 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3996 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3997 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3998 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 3999 Torque Converter Clutch Solenoid: Service and Repair Solenoid Body Assembly Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the drain plug and drain the fluid. 3. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. Disconnect the solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the gasket should be reused. Remove the 16 transmission fluid pan screws, fluid pan and gasket. 5. Remove the transmission fluid filter. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4000 6. CAUTION: Do not damage the solenoid body connector pins. Remove the solenoid body bolts and remove the solenoid body by pulling down on the solenoid body and pushing down on the connector from the other side of the case. Installation 1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean automatic transmission fluid. 2. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur. Install the solenoid body. Tighten the bolts in sequence shown. ^ Tighten to 8 Nm (71 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4001 3. CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be damaged. NOTE: Make sure that the fluid filter seals are correctly seated on the filter. Lubricate the seals and install the transmission fluid filter. ^ Tighten to 10 Nm (89 inch lbs.) 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage, if not damaged, the gasket should be reused. Install the transmission fluid pan and gasket and loosely install the screws. 5. Tighten the screws in a crisscross sequence. ^ Tighten to 11 Nm (8 ft. lbs.) 6. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the specification. NOTE: Always install new O-ring seals on vehicle harness connector. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission connector and connect the connector. ^ Tighten to 5 Nm (44 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4002 7. Fill the transmission. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 (TCIL) The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM Control Module: Customer Interest A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM TSB 07-6-3 04/02/07 6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac MERCURY: 2006-2007 Mountaineer ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition vehicles may exhibit the following diagnostic trouble codes in the transmission control module (1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657, P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083, P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination at the mechatronic assembly. ACTION Follow the Service Procedure steps to correct the condition. NOTE IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM BARRIER STRIP. SERVICE PROCEDURE Remove the source of contamination from the transmission control unit (TCU)/solenoid connections and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent recurrence. 1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01. 2. Remove the six (6) long fasteners from the TCM unit. (Figure 1) 3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of the main control during this procedure. NOTE IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS SYSTEM. 4. Inspect the TCM at the following locations for metal chips or other metallic contamination. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4018 a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination. (Figure 2) b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure 3 and 4) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4019 c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure 5) 5. Prior to installation of the protective strip, remove all machining chips and or other metallic contamination from these areas with a clean, lint free cloth. 6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam barrier strip is installed). 7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first, "point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM, Section 307-01. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4020 8. Reinstall the mechatronic assembly following the WSM, Section 307-01. 9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01. 10. Set the transmission fluid level following the WSM, Section 307-01. 11. Clear all DTC(s) from the TCM. 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 070603A 2006-2007 2.6 Hrs. Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) 070603A 2007 Expedition 6R75 2.7 Hrs. Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) DEALER CODING CONDITION BASIC PART NO. CODE 14B167 49 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM Control Module: All Technical Service Bulletins A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM TSB 07-6-3 04/02/07 6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac MERCURY: 2006-2007 Mountaineer ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition vehicles may exhibit the following diagnostic trouble codes in the transmission control module (1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657, P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083, P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination at the mechatronic assembly. ACTION Follow the Service Procedure steps to correct the condition. NOTE IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM BARRIER STRIP. SERVICE PROCEDURE Remove the source of contamination from the transmission control unit (TCU)/solenoid connections and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent recurrence. 1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01. 2. Remove the six (6) long fasteners from the TCM unit. (Figure 1) 3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of the main control during this procedure. NOTE IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS SYSTEM. 4. Inspect the TCM at the following locations for metal chips or other metallic contamination. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4026 a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination. (Figure 2) b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure 3 and 4) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4027 c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure 5) 5. Prior to installation of the protective strip, remove all machining chips and or other metallic contamination from these areas with a clean, lint free cloth. 6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam barrier strip is installed). 7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first, "point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM, Section 307-01. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4028 8. Reinstall the mechatronic assembly following the WSM, Section 307-01. 9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01. 10. Set the transmission fluid level following the WSM, Section 307-01. 11. Clear all DTC(s) from the TCM. 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 070603A 2006-2007 2.6 Hrs. Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) 070603A 2007 Expedition 6R75 2.7 Hrs. Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) DEALER CODING CONDITION BASIC PART NO. CODE 14B167 49 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions Brake Switch - TCC: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4035 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4036 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4037 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4038 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4039 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4040 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4041 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4042 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4043 Brake Switch - TCC: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4044 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4045 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4046 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4047 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4048 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4049 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4050 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4051 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Page 4052 Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Overdrive Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4057 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4058 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4059 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4060 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4061 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4062 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4063 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4064 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4065 Overdrive Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4066 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4067 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4068 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4069 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4070 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4071 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4072 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4073 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor/Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4078 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4079 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4080 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4081 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4082 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4083 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4084 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4085 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4086 Throttle Position Sensor/Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4087 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4088 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4089 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4090 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4091 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4092 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4093 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4094 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions Transmission Mode Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 4099 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 4100 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 4101 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 4102 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 4103 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 4104 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 4105 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 4106 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 4107 Transmission Mode Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 4108 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 4109 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 4110 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 4111 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 4112 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 4113 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 4114 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 4115 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Control (TC) Switch Transmission Mode Switch: Description and Operation Transmission Control (TC) Switch Transmission Control (TC) Switch The transmission control (TC) switch is a momentary contact switch located on the selector lever knob. Pushing the TC switch will either disengage or engage the overdrive function of the transmission. If OVERDRIVE is disengaged, the message O/D OFF will illuminate on the instrument panel. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Control (TC) Switch > Page 4118 Transmission Mode Switch: Description and Operation Transmission Control Switch (TCS) TRANSMISSION CONTROL SWITCH (TCS) Typical Transmission Control Switch (TCS) Typical Transmission Control Switch (TCS) The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature, the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage overdrive. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Page 4119 Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch Removal 1. Remove the transmission selector lever knob. 2. Remove the transmission control switch from the knob. Installation 1. Install the transmission control switch into the knob. 2. Install the transmission selector lever knob. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4125 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4126 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4127 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4128 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4129 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4130 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4131 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4132 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4133 Transmission Position Switch/Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4134 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4135 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4136 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4137 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4138 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4139 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4140 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4141 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4142 C167 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4143 Transmission Position Switch/Sensor: Testing and Inspection Digital Transmission Range (TR) Sensor Diagnosis Chart Digital Transmission Range (TR) Sensor Diagnosis Chart Wiggle Test Information for Open/Shorts ^ TR4, TR3A, TR2 and TR1 are all closed in PARK. PARK is a good position to check for intermittent open circuits (with scan tool monitoring TRD). ^ TR4, TR3A, TR2 and TR1 are all open in OVERDRIVE, so OVERDRIVE is a good position to check for shorts to ground. To determine the shorted components while observing TRD, unplug the TR and determine if the short goes away. If the short is still present unplug the transmission harness and determine if the short goes away. If the short is still present, then the short is in the PCM or vehicle harness. Remove the suspect circuit(s) wire terminal from the PCM connector. If the short is still present, then the PCM has an internal failure, otherwise the failure is in the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4144 Transmission Position Switch/Sensor: Adjustments Transmission Range (TR) Sensor Adjustment Special Tool(s) Adjust 1. With the vehicle in NEUTRAL, position it on a hoist For additional information, refer to Maintenance/Service and Repair. 2. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the connector. 4. Disconnect the digital transmission range (TR) sensor electrical connector. 5. Remove the range selector lever cable end from the manual control lever. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4145 6. Remove the outer manual control lever. 7. Loosen but do not remove the digital TR sensor screws. 8. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. ^ Tighten to 8 Nm (71 inch lbs.) 9. Install the outer manual lever. ^ Tighten to 48 Nm (35 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4146 10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable end onto the manual control lever. 11. Reconnect the digital TR sensor electrical connector. 12. Move the rubber boot back over the connector. 13. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4147 14. Verify that the selector lever cable is adjusted correctly. 15. Verify that the vehicle will start in PARK and NEUTRAL and that the reverse lamps illuminate in REVERSE. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4148 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the connector. 4. Disconnect the digital transmission range (TR) sensor electrical connector. 5. Remove the selector lever cable from the manual control lever. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4149 6. Remove the outer manual control lever. 7. Remove the digital TR sensor. Installation 1. CAUTION: The digital transmission range sensor must fit flush against the boss on the case to prevent damage to the sensor. Install the digital TR sensor and 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 be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4150 ^ Tighten to 8 Nm (71 inch lbs.) 3. Install the outer manual lever. ^ Tighten to 48 Nm (35 ft. lbs.) 4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable to the manual control lever. 5. Connect the digital TR sensor electrical connector. 6. Move the rubber boot back over the connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4151 7. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. 8. Verify that the selector lever cable is adjusted correctly. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Locations > Output Shaft Speed (OSS) Sensor View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Locations > Output Shaft Speed (OSS) Sensor > Page 4156 View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Locations > Output Shaft Speed (OSS) Sensor > Page 4157 View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4160 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4161 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4162 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4163 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4164 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4165 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4166 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4167 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4168 Transmission Speed Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4169 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4170 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4171 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4172 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4173 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4174 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4175 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4176 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4177 Transmission Speed Sensor: Connector Views C193 C143 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4178 C164 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 4181 6. Remove the selector lever cable and bracket. 7. Disconnect the turbine shaft speed (TSS) sensor electrical connector. 8. Remove the TSS sensor. 1 Remove the TSS sensor screw. 2 Remove the TSS sensor from the transmission. ^ Inspect the TSS sensor O-ring for damage. If damaged, install a new O-ring. Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the TSS sensor into the transmission. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 4182 2 Tighten the TSS sensor screw. ^ Tighten to 14 Nm (10 ft. lbs.) 2. Connect the TSS sensor electrical connector. 3. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable and bracket. ^ Tighten to 40 Nm (30 ft. lbs.) 4. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 4183 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Install the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 ft. lbs.) 7. Install the front driveshaft to the front differential. ^ Tighten to 18 Nm (13 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 4184 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 4185 6. Remove the selector lever cable and bracket. 7. Disconnect the heated oxygen sensor (HO2S) sensor connector from the transmission case. 8. Disconnect the output shaft speed (OSS) sensor electrical connector. 9. Remove the 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, install a new O-ring. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 4186 Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the OSS sensor into the transmission. 2 Tighten the OSS sensor screw. ^ Tighten to 14 Nm (10 ft. lbs.) 2. Connect the OSS sensor electrical connector. 3. Connect the HO2S connector to the transmission case. 4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 4187 cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable and bracket. ^ Tighten to 40 Nm (30 ft. lbs.) 5. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. 4WD vehicles 6. Install the front driveshaft in the vehicle. 7. Install the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 4188 8. Install the front driveshaft to the front differential. ^ Tighten to 18 Nm (13 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 4189 Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor Intermediate Shaft Speed Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 4190 6. Remove the selector lever cable and bracket. 7. Disconnect the intermediate shaft speed sensor electrical connector. 8. Remove the intermediate shaft speed sensor. 1 Remove the intermediate shaft speed sensor screw. 2 Remove the intermediate shaft speed sensor from the transmission. ^ Inspect the intermediate shaft speed sensor O-ring for damage. If damaged, install a new O-ring. Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the intermediate shaft speed sensor into the transmission. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 4191 2 Tighten the intermediate shaft speed sensor screw. ^ Tighten to 14 Nm (10 ft. lbs.) 2. Connect the intermediate shaft speed sensor electrical connector. 3. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable and bracket. ^ Tighten to 40 Nm (30 ft. lbs.) 4. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 4192 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Install the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 ft. lbs.) 7. Install the front driveshaft to the front differential. ^ Tighten to 18 Nm (13 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4197 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4198 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4199 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4200 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4201 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4202 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4203 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4204 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4205 Transmission Temperature Sensor/Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4206 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4207 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4208 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4209 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4210 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4211 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4212 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4213 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 09-1-2 > Jan > 09 > Engine Controls - MIL ON/DTC P0456 Stored In ECM PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC P0456 Stored In ECM TSB 09-1-2 01/26/09 MALFUNCTION INDICATOR LAMP (MIL) ON WITH DIAGNOSTIC TROUBLE CODE (DTC) P0456 - BUILT ON OR BEFORE 4/14/2008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-16-10 to add a production fix date. ISSUE Some 2006-2008 Explorer, Mountaineer and 2007-2008 Sport Trac vehicles built on or before 4/14/2008 may exhibit a malfunction indicator lamp (MIL) on with diagnostic trouble code (DTC) P0456 in the powertrain control module (PCM) memory with no other PCM trouble codes. ACTION Follow the Service Procedure steps to reprogram the PCM and the transmission control module (TCM) if necessary. SERVICE PROCEDURE Use the correct procedure for the vehicle application you are working on. For all 4.0L engines follow Procedure A and for all 4.6L engines follow Procedure B. Procedure A (4.0L Engine) 1. Reprogram the PCM to the latest calibration using Integrated Diagnostic System (IDS) release 52.8 and higher or 53.1 and higher. This new calibration is not included in the VCM 2007.11 DVD. Calibration files may also be obtained at the website. Procedure B (4.6L Engine) NOTE VEHICLES EQUIPPED WITH A PCM AND TCM, REQUIRE A COORDINATED REPROGRAMMING. THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS OUTLINED BY THE IDS. FAILURE TO FOLLOW THE KEY CYCLE PROCEDURE WITHOUT WAITING FOR THE IDS PROMPTS, WILL CAUSE THE COORDINATED REPROGRAMMING TO FAIL. THE PCM WILL BE UPDATED BUT THE 1CM WILL NOT BE UPDATED AND THE NEW FILES WILL NOT BE INSTALLED. IT IS CRITICAL TO FOLLOW THE IDS PROMPTS 1. Install IDS / Portable Diagnostic Software (PDS) or equivalent and identify (ID) the vehicle. 2. Update the PCM and TCM calibration using IDS release 52.8 and higher or 53.1 and higher. This new calibration is not included in the VCM 2007.11 DVD. Calibration files may also be obtained at the website. Since the TCM cannot be independently reprogrammed, reprogram the PCM to ensure that engine and transmission calibrations are updated to the latest level simultaneously. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. (3) Choose Reset KAM. (4) Then Choose TCM. b. Using PDS: Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 09-1-2 > Jan > 09 > Engine Controls - MIL ON/DTC P0456 Stored In ECM > Page 4222 (1) Choose all Tests and Calibrations. (2) Scroll down the menu and Choose Reset TCM KAM. NOTE FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. NOTE DO NOT CLEAR THE PCM KAM. (3) Verify that the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). 4. If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. 5. Drive unit to perform adaptive shift strategy learn. a. Accelerate from rest with light throttle to 15 MPH (24 Km/h), remove foot from accelerator pedal. b. Brake very gently to a complete stop (allow at least six (6) seconds). c. Repeat steps (a-b) five (5) times in the dealership parking lot or similar setting. d. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. e. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts must occur at engine speeds between 1300-1800 RPM. f. Continue to accelerate gently to 50 MPH (80 Km/h) or the 5-6 upshift. g. Brake gently to a complete stop and hold foot on brake for at least 10 seconds. h. Repeat Steps (e-f) a total of three (3) times. NOTE AUTHORIZATION DECAL NOT REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 090102A 2006-2008 Explorer, 0.3 Hr. Mountaineer 2007-2008 Explorer Sport Trac 4.0L Engine: Check DTCs, Reprogram The PCM (Do Not Use With 12650D) 090102B 2006-2008 Explorer, 1.0 Hr. Mountaineer 2007-2008 Explorer Sport Trac 4.6L Engine: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear KAM And Perform Road Tests (Do Not Use With 12650D) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 09-1-2 > Jan > 09 > Engine Controls - MIL ON/DTC P0456 Stored In ECM > Page 4223 DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 08-24-4 > Dec > 08 > A/T, Engine Controls - Low Speed Driveline Bump PROM - Programmable Read Only Memory: Customer Interest A/T, Engine Controls - Low Speed Driveline Bump TSB 08-24-4 12/08/08 DRIVELINE BUMP WHILE BRAKING - BELOW 10 MPH (16 KM/H) FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-4-16 to update the Service Procedure. ISSUE Some 2006-2008 Explorer, Mountaineer and 2007-2008 Explorer Sport Trac vehicles equipped with a 6R60 transmission may exhibit a bump feeling while braking to a stop less than 10 MPH (16 Km/h). The following procedure will improve the bump felt while braking to a stop. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE DO NOT ATTEMPT TO REPLACE THE MECHATRONIC UNIT. MECHATRONIC REPAIR / REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install Integrated Diagnostic System (IDS) / Portable Diagnostic Software (PDS) or equivalent and ID the vehicle. 2. Update the powertrain control module (PCM) and transmission control module (TCM) calibration using IDS release 57.11 and higher or 58.2 and higher. This new calibration is not included in the VCM 2008.11 DVD. Calibration files may also be obtained at the website. Since the TCM cannot be independently reprogrammed, reprogram the Programmable Module Installation (PMI) function to ensure that engine and transmission calibrations are updated to the latest level simultaneously. NOTE AUTHORIZATION DECAL NOT REQUIRED. a. Verify that the TCM Calibration shows 8L2P-7J104-AC, (8L2P-7J 104-CC for builds after 12/3/2007) part number after reprogramming is complete. Select the following from the IDS tool, Toolbox, Powertrain, OBD Test Modes, Mode Level 9 Vehicle Info, TCM Cal Part Number. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. (3) Choose Reset KAM. (4) Then Choose TCM. b. Using PDS: (1) Choose all Tests and Calibrations. (2) Scroll down the menu and Choose Reset TCM KAM. NOTE Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 08-24-4 > Dec > 08 > A/T, Engine Controls - Low Speed Driveline Bump > Page 4228 FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. IT IS CRITICAL THAT TCM KAM BE CLEARED PRIOR TO RELEARNING THE ADAPTIVE TABLES FOR THE TRANSMISSION. NOTE DO NOT CLEAR THE PCM KAM. 4. Verify that the transmission fluid temperature (TFT) PID is above 175° F (80° C). If it is not at 175° F (80° C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175° F (80° C) OR ABOVE BEFORE PROCEEDING TO STEP 5. NOTE PERFORM ADAPTIVE SHIFT STRATEGY LEARN ON LEVEL SURFACE ROAD. 5. Drive unit to perform adaptive shift strategy learn. a. Accelerate from rest with light throttle to 15 MPH (24 Km/h), remove foot from accelerator pedal. b. Brake very gently to a complete stop (allow at least six (6) seconds). c. Repeat steps (a-b) five (5) times in the dealership parking lot or similar setting. d. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts occur at engine speeds between 1700-2000 RPM. e. Continue to accelerate gently to 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for at least ten (10) seconds. g. Repeat Steps (d-f) a total of three (3) times. NOTE THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER, SEVERAL DAYS OF DRIVING MAY BE REQUIRED FOR THE TRANSMISSION TO FULLY ADAPT. 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 082404A 2006-2008 Explorer, 1.0 Hr. Mountaineer 2007-2008 Explorer Sport Trac 6R60 Transmission: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear KAM And Perform Road Tests, Authorization Decal Not Required (Do Not Use With 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 08-24-4 > Dec > 08 > A/T, Engine Controls - Low Speed Driveline Bump > Page 4229 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start TSB 08-18-2 09/15/08 MIL ON - P0506 AND/OR P0505 - HESITATION/LOSS OF RPM/DIFFICULTY STARTING/LOW IDLE RPM FORD: 2005-2007 Crown Victoria 2006 Mustang, Mustang 2004-2006 F-150, F-150 2005-2006 E-350, E-450, F-Super Duty 2006 F-53 Motorhome Chassis 2006-2007 Explorer Sport Trac, Explorer LINCOLN: 2005-2007 Town Car 2006 Mark LT MERCURY: 2005-2007 Grand Marquis 2006-2007 Mountaineer, Mountaineer This article supersedes TSB(s) 08-5-13, 07-23-12 and 06-25-8 to update the Service Procedure. ISSUE Some 2004-2006 4.6L and 5.4L F-150 (excluding F-150 Heritage), 2006 5.4L Mark LT, 2005-2006 6.8L E-350 / E-450, 2005-2006 6.8L F-Super Duty (F-250 to F-550), 2006 6.8L F-53 Motorhome Chassis, 2006-2007 4.0L Explorer 4 dr, 2007 4.0L Explorer Sport Trac, 2006-2007 4.0L Mountaineer, 2006 4.0L Mustang, 2006 - 2007 4.6L 3V Explorer / Explorer Sport Trac / Mountaineer, 2006 4.6L 3V Mustang, and 2005-2007 Crown Vic / Grand Marquis / Towncar vehicles may exhibit one or more of the following symptoms: drive-away hesitation, loss of RPM on deceleration, difficulty starting, and/or idle RPM less than desired. Malfunction indicator lamp (MIL) may be illuminated with diagnostic trouble codes (DTCs) P0506 and/or P0505. These conditions may appear after battery disconnect, dead battery condition, or keep alive memory (KAM) reset. The symptoms may be due to engine deposits in the throttle leading to air[low less than desired. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 53.9 and higher or 54.1 and higher. This new calibration is not included in the VCM 2008.1 DVD. Calibration files may also be obtained at the website. The calibration contains a sludge compensation strategy for the throttle body. 2. Turn the key off to re-initialize the PCM. This will allow the sludge compensation strategy to learn. 3. With the vehicle in park or neutral and A/C off, start vehicle and allow engine to reach normal operating temperature(greater than 170 °F (77 °C) coolant temperature). Run an additional 5 minutes to allow sufficient learning time. 4. While the engine is running, using IDS datalogger or equivalent, check the PID value of ETC_TRIM. a. If ETC_TRIM value is 3.5 degrees, and/or DTC PuSE is present, then replace the electronic throttle body (ETB), following Workshop Manual (WSM), Section 303-04B. b. If ETC_TRIM value is less than 3.5 degrees and DTC PuSE is not present, but driveability concerns persist, the ETB is not the likely cause of the concern and replacement is not necessary. Continue with normal PC/ED diagnostics. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start > Page 4234 NOTE VEHICLES EQUIPPED WITH A PCM AND TCM REQUIRE COORDINATED REPROGRAMMING. THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS OUTLINED BY THE IDS. FAILURE TO FOLLOW THE KEY CYCLE PROCEDURE WITHOUT WAITING FOR THE IDS PROMPTS, WILL CAUSE THE COORDINATED REPROGRAMMING TO FAIL. THE PCM WILL BE UPDATED BUT THE 1CM WILL NOT BE UPDATED AND NEW FILES WILL NOT BE INSTALLED. IT IS CRITICAL TO FOLLOW THE IDS PROMPTS. SOME VEHICLES MAY REQUIRE SEVERAL DAYS OF DRIVING FOR THE TRANSMISSION TO FULLY ADAPT. REPROGRAMMING CONCERNS/ERRORS MAY BE CAUSED BY THE DATA LINK CONNECTOR (DLC) OR VEHICLE COMMUNICATION MODULE (VCM) BECOMING DISCONNECTED, LOW BATTERIES ON THE INTEGRATED DIAGNOSTIC SYSTEM (IDS) OR THE IDS GOING INTO ANY TYPE OF SLEEP MODE, OR LOW VEHICLE BATTERY VOLTAGE. IF THERE WAS AN INTERRUPTION DURING REPROGRAMMING, MAKE SURE THE ORIGINAL IDS SESSION THAT WAS CREATED FOR THE VEHICLE IS NOT DELETED. IF THE ORIGINAL VEHICLE SESSION IS NOT USED OR DELETED BEFORE THE MODULES ARE COMPLETELY REPROGRAMMED, FURTHER REPROGRAMMING ERRORS CAN OCCUR. THE MODULE RECOVERY PROCEDURE IS NO LONGER AVAILABLE AND IT IS CRITICAL THAT MODULE SWAPPING IS NOT PERFORMED FROM VEHICLE TO VEHICLE. TO REGAIN COMMUNICATION WITH A MODULE THAT HAS BEEN ERASED DURING REPROGRAMMING, RESUME THE ORIGINAL SESSION ONCE THE IDS IS RE-BOOTED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081802A 2004-2006 F-150 0.4 Hr. 4.6L/5.4L, 2006 Mark LT, Econoline 350/450 6.8L 2005-2006 F-Super Duty 6.8L, 2006-2007 Explorer/Mountaineer 4.0L, 2007 Explorer Sport Trac 4.0L, 2006 Mustang 4.OL, 2005-2007 Crown Victoria, Town Car, Grand Marquis: Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Authorization Decal NOT Necessary. (Do Not Use With 9926A, 12650D) 081802A 2006-2007 1.0 Hr. Explorer/Mountaineer 4.6L, 2007 Explorer Sport Trac 4.6L: Check For DICs And Reprogram The PCM And 1CM, Includes Time To Monitor ETC_Trim Value, Authorization Decal NOT Necessary. (Do Not Use With 9926A, 12650D) 081802B 2004-2006 F-150 5.4L, 0.9 Hr. 2006 Mark LT: Check For DTCs And Reprogram The PCM, Includes Time To Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start > Page 4235 Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2004-2006 F-150 4.6L: 0.8 Hr. Check For DTCs And Reprogram The PCM Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2005-2006 Econoline 6.8L: 1.1 Hrs. Check For DTCs And Reprogram The PCM Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2005-2006 F-Super Duty 0.9 Hr. 6.8L: Check For DTCs And Reprogram The PCM Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2006-2007 Explorer, 1.4 Hrs. Mountaineer 2007 Explorer Sport Trac 4.6L: Check For DTCs And Reprogram The PCM And TCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2006-2007 Explorer, 0.8 Hr. Mountaineer 2007 Explorer Sport Trac 4.0L: Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2005-2007 Crown Victoria, 0.8 Hr. Town Car, Grand Marquis: Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start > Page 4236 Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2006 Mustang 4.0L/4.6L: 0.8 Hr. Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 08-9-5 > May > 08 > Engine Controls - Hard Start/Rough Idle After Hot Soak PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Hard Start/Rough Idle After Hot Soak TSB 08-9-5 05/12/08 4.0L/4.6L - HARD START/ROUGH RUNNING - AFTER LONG HOT SOAK / DIP IN RPM WHEN COMING TO A STOP - BUILT ON OR BEFORE 4/212008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer ISSUE Some 2006-2008 Explorer 4dr, Mountaineer and 2007-2008 Sport Trac vehicles equipped with 4.0L or 4.6L engine and built on or before 4/2/2008 may exhibit a dip in RPM below normal idle level of 600 RPM on deceleration with no diagnostic trouble codes (DTCs) present or a hard start / rough running condition after a long hot soak. ACTION Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 54.6 and higher or 55.1. This new calibration is not included in the VCM 2008.3 DVD. Calibration files may also be obtained at the website. 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 080905A 2006-2008 0.3 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Check For DTCs And Reprogram The PCM Authorization Decal Not Required (Do Not Use With 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 07-23-2 > Nov > 07 > A/T - Delayed Engagement/Hesitation/Bump on Decel PROM - Programmable Read Only Memory: Customer Interest A/T - Delayed Engagement/Hesitation/Bump on Decel TSB 07-23-2 11/26/07 6R60 TRANSMISSION EQUIPPED VEHICLES ONLY - BUMP WHILE BRAKING - BELOW 10 MPH (16 KM/H), DELAYED ENGAGEMENT, HESITATION ON TIP-IN AFTER BRAKING FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer This article supersedes TSB 07-13-8 to update the Service Procedure. ISSUE Some 2006-2008 Explorer 4dr, Mountaineer and 2007-2008 Explorer Sport Trac vehicles equipped with 6R60 transmission may exhibit a bump feeling while braking to a stop less than 10 MPH (16 Km/h). Some vehicles built prior to 05/4/2006 may exhibit the following symptoms: ^ Delayed engagements into Drive from Park Neutral or Reverse. ^ Hesitation upon tip-in after braking to a stop. This fixes the bump while braking to a stop, improves the delayed engagements and reduces the incidence of tip-in hesitation while accelerating from a stop. ACTION Follow the Service Procedure steps to reprogram the transmission control module (1CM) and the powertrain control module (PCM). Some tip-in hesitation is normal on this transmission in order to provide smooth operation. This calibration update will help to improve the condition. The harsh bump while braking to a stop will be eliminated. Several days of driving may be required for the transmission to fully adapt. SERVICE PROCEDURE NOTE DO NOT ATTEMPT TO REPLACE THE MECHATRONIC UNIT. MECHATRONIC REPAIR/REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install IDS/PDS or equivalent and ID the vehicle. 2. Update the PCM and TCM calibration using IDS release 51.8 and higher or 52.1 and higher. Calibration files may also be obtained at the website. Since the TCM cannot be independently reprogrammed, reprogram the PCM to ensure that engine and transmission calibrations are updated to the latest level simultaneously. 3. Clear 1CM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. (3) Choose Reset KAM. (4) Then Choose 1CM. b. Using PDS: (1) Choose all Tests and Calibrations. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 07-23-2 > Nov > 07 > A/T - Delayed Engagement/Hesitation/Bump on Decel > Page 4245 (2) Scroll down the menu and Choose Reset TCM KAM. NOTE FOR PDS, RESET 1CM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. NOTE DO NOT CLEAR THE PCM KAM. 4. Verify that the transmission fluid temperature (TFT) PID is above 175° F (80°C). If it is not at 175° F (80° C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175° F (80° C) OR ABOVE BEFORE PROCEEDING TO STEP 5. 5. Drive unit to perform adaptive shift strategy learn. a. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts must occur at engine speeds between 1300-1800 RPM. b. Continue to accelerate gently to 50 MPH (80 Km/h) so that the transmission shifts into 6th gear. c. Brake gently to a complete stop and hold foot on brake for at least 15 seconds. d. Repeat Steps (a-c) a total of five (5) times. 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 072302A 2006-2008 Explorer, 0.9 Hr. Mountaineer 2007-2008 Explorer Sport Trac 4.6L 6R60 Transmission: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear KAM And Perform Road Tests (Do Not Use With 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 06-17-13 > Sep > 06 > Engine Controls - Surge/Hesitation/T/C Cycling/A/C Perf. PROM - Programmable Read Only Memory: Customer Interest Engine Controls Surge/Hesitation/T/C Cycling/A/C Perf. TSB 06-17-13 09/04/06 CALIBRATION UPDATE 4.0L - VARIOUS SYMPTOMS - SURGE, HESITATION, TORQUE CONVERTER CYCLING, NO UP SHIFT AFTER A FORCED DOWNSHIFT, AND POOR A/C PERFORMANCE FORD: 2006-2007 Explorer 2007 Explorer Sport Trac MERCURY: 2006-2007 Mountaineer ISSUE Some 2006-2007 Explorer 4dr/Mountaineer and 2007 Sport Trac vehicles equipped with a 4.0L engine may exhibit a surge at steady speeds, transmission torque converter clutch cycling or hanging in a lower gear after a forced downshift during cruise control operation when operated in high ambient conditions. In addition, these vehicles may exhibit a cold hesitation/surge, engine fan noise and/or varying A/C discharge temperatures "ONLY" during low vehicle speed intermittently. ACTION Reprogram the powertrain control module (PCM) to the latest calibration using IDS release B43.16 and higher or B44.8 and higher. This new calibration is not included in the B44 CD. Calibration files may also be obtained at website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061713A 2006-2007 0.4 Hr. Explorer/Mountaineer, 2007 Explorer Sport Trac 4.0L: Check Diagnostic Trouble Codes And Reprogram The PCM (Do Not Use With 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-1-2 > Jan > 09 > Engine Controls - MIL ON/DTC P0456 Stored In ECM PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0456 Stored In ECM TSB 09-1-2 01/26/09 MALFUNCTION INDICATOR LAMP (MIL) ON WITH DIAGNOSTIC TROUBLE CODE (DTC) P0456 - BUILT ON OR BEFORE 4/14/2008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-16-10 to add a production fix date. ISSUE Some 2006-2008 Explorer, Mountaineer and 2007-2008 Sport Trac vehicles built on or before 4/14/2008 may exhibit a malfunction indicator lamp (MIL) on with diagnostic trouble code (DTC) P0456 in the powertrain control module (PCM) memory with no other PCM trouble codes. ACTION Follow the Service Procedure steps to reprogram the PCM and the transmission control module (TCM) if necessary. SERVICE PROCEDURE Use the correct procedure for the vehicle application you are working on. For all 4.0L engines follow Procedure A and for all 4.6L engines follow Procedure B. Procedure A (4.0L Engine) 1. Reprogram the PCM to the latest calibration using Integrated Diagnostic System (IDS) release 52.8 and higher or 53.1 and higher. This new calibration is not included in the VCM 2007.11 DVD. Calibration files may also be obtained at the website. Procedure B (4.6L Engine) NOTE VEHICLES EQUIPPED WITH A PCM AND TCM, REQUIRE A COORDINATED REPROGRAMMING. THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS OUTLINED BY THE IDS. FAILURE TO FOLLOW THE KEY CYCLE PROCEDURE WITHOUT WAITING FOR THE IDS PROMPTS, WILL CAUSE THE COORDINATED REPROGRAMMING TO FAIL. THE PCM WILL BE UPDATED BUT THE 1CM WILL NOT BE UPDATED AND THE NEW FILES WILL NOT BE INSTALLED. IT IS CRITICAL TO FOLLOW THE IDS PROMPTS 1. Install IDS / Portable Diagnostic Software (PDS) or equivalent and identify (ID) the vehicle. 2. Update the PCM and TCM calibration using IDS release 52.8 and higher or 53.1 and higher. This new calibration is not included in the VCM 2007.11 DVD. Calibration files may also be obtained at the website. Since the TCM cannot be independently reprogrammed, reprogram the PCM to ensure that engine and transmission calibrations are updated to the latest level simultaneously. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. (3) Choose Reset KAM. (4) Then Choose TCM. b. Using PDS: Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-1-2 > Jan > 09 > Engine Controls - MIL ON/DTC P0456 Stored In ECM > Page 4255 (1) Choose all Tests and Calibrations. (2) Scroll down the menu and Choose Reset TCM KAM. NOTE FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. NOTE DO NOT CLEAR THE PCM KAM. (3) Verify that the transmission fluid temperature (TFT) PID is above 175 °F (80 °C). 4. If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5. 5. Drive unit to perform adaptive shift strategy learn. a. Accelerate from rest with light throttle to 15 MPH (24 Km/h), remove foot from accelerator pedal. b. Brake very gently to a complete stop (allow at least six (6) seconds). c. Repeat steps (a-b) five (5) times in the dealership parking lot or similar setting. d. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. e. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts must occur at engine speeds between 1300-1800 RPM. f. Continue to accelerate gently to 50 MPH (80 Km/h) or the 5-6 upshift. g. Brake gently to a complete stop and hold foot on brake for at least 10 seconds. h. Repeat Steps (e-f) a total of three (3) times. NOTE AUTHORIZATION DECAL NOT REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 090102A 2006-2008 Explorer, 0.3 Hr. Mountaineer 2007-2008 Explorer Sport Trac 4.0L Engine: Check DTCs, Reprogram The PCM (Do Not Use With 12650D) 090102B 2006-2008 Explorer, 1.0 Hr. Mountaineer 2007-2008 Explorer Sport Trac 4.6L Engine: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear KAM And Perform Road Tests (Do Not Use With 12650D) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 09-1-2 > Jan > 09 > Engine Controls - MIL ON/DTC P0456 Stored In ECM > Page 4256 DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-24-4 > Dec > 08 > A/T, Engine Controls - Low Speed Driveline Bump PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T, Engine Controls Low Speed Driveline Bump TSB 08-24-4 12/08/08 DRIVELINE BUMP WHILE BRAKING - BELOW 10 MPH (16 KM/H) FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-4-16 to update the Service Procedure. ISSUE Some 2006-2008 Explorer, Mountaineer and 2007-2008 Explorer Sport Trac vehicles equipped with a 6R60 transmission may exhibit a bump feeling while braking to a stop less than 10 MPH (16 Km/h). The following procedure will improve the bump felt while braking to a stop. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE DO NOT ATTEMPT TO REPLACE THE MECHATRONIC UNIT. MECHATRONIC REPAIR / REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install Integrated Diagnostic System (IDS) / Portable Diagnostic Software (PDS) or equivalent and ID the vehicle. 2. Update the powertrain control module (PCM) and transmission control module (TCM) calibration using IDS release 57.11 and higher or 58.2 and higher. This new calibration is not included in the VCM 2008.11 DVD. Calibration files may also be obtained at the website. Since the TCM cannot be independently reprogrammed, reprogram the Programmable Module Installation (PMI) function to ensure that engine and transmission calibrations are updated to the latest level simultaneously. NOTE AUTHORIZATION DECAL NOT REQUIRED. a. Verify that the TCM Calibration shows 8L2P-7J104-AC, (8L2P-7J 104-CC for builds after 12/3/2007) part number after reprogramming is complete. Select the following from the IDS tool, Toolbox, Powertrain, OBD Test Modes, Mode Level 9 Vehicle Info, TCM Cal Part Number. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. (3) Choose Reset KAM. (4) Then Choose TCM. b. Using PDS: (1) Choose all Tests and Calibrations. (2) Scroll down the menu and Choose Reset TCM KAM. NOTE Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-24-4 > Dec > 08 > A/T, Engine Controls - Low Speed Driveline Bump > Page 4261 FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. IT IS CRITICAL THAT TCM KAM BE CLEARED PRIOR TO RELEARNING THE ADAPTIVE TABLES FOR THE TRANSMISSION. NOTE DO NOT CLEAR THE PCM KAM. 4. Verify that the transmission fluid temperature (TFT) PID is above 175° F (80° C). If it is not at 175° F (80° C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175° F (80° C) OR ABOVE BEFORE PROCEEDING TO STEP 5. NOTE PERFORM ADAPTIVE SHIFT STRATEGY LEARN ON LEVEL SURFACE ROAD. 5. Drive unit to perform adaptive shift strategy learn. a. Accelerate from rest with light throttle to 15 MPH (24 Km/h), remove foot from accelerator pedal. b. Brake very gently to a complete stop (allow at least six (6) seconds). c. Repeat steps (a-b) five (5) times in the dealership parking lot or similar setting. d. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts occur at engine speeds between 1700-2000 RPM. e. Continue to accelerate gently to 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for at least ten (10) seconds. g. Repeat Steps (d-f) a total of three (3) times. NOTE THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER, SEVERAL DAYS OF DRIVING MAY BE REQUIRED FOR THE TRANSMISSION TO FULLY ADAPT. 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 082404A 2006-2008 Explorer, 1.0 Hr. Mountaineer 2007-2008 Explorer Sport Trac 6R60 Transmission: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear KAM And Perform Road Tests, Authorization Decal Not Required (Do Not Use With 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-24-4 > Dec > 08 > A/T, Engine Controls - Low Speed Driveline Bump > Page 4262 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start TSB 08-18-2 09/15/08 MIL ON - P0506 AND/OR P0505 - HESITATION/LOSS OF RPM/DIFFICULTY STARTING/LOW IDLE RPM FORD: 2005-2007 Crown Victoria 2006 Mustang, Mustang 2004-2006 F-150, F-150 2005-2006 E-350, E-450, F-Super Duty 2006 F-53 Motorhome Chassis 2006-2007 Explorer Sport Trac, Explorer LINCOLN: 2005-2007 Town Car 2006 Mark LT MERCURY: 2005-2007 Grand Marquis 2006-2007 Mountaineer, Mountaineer This article supersedes TSB(s) 08-5-13, 07-23-12 and 06-25-8 to update the Service Procedure. ISSUE Some 2004-2006 4.6L and 5.4L F-150 (excluding F-150 Heritage), 2006 5.4L Mark LT, 2005-2006 6.8L E-350 / E-450, 2005-2006 6.8L F-Super Duty (F-250 to F-550), 2006 6.8L F-53 Motorhome Chassis, 2006-2007 4.0L Explorer 4 dr, 2007 4.0L Explorer Sport Trac, 2006-2007 4.0L Mountaineer, 2006 4.0L Mustang, 2006 - 2007 4.6L 3V Explorer / Explorer Sport Trac / Mountaineer, 2006 4.6L 3V Mustang, and 2005-2007 Crown Vic / Grand Marquis / Towncar vehicles may exhibit one or more of the following symptoms: drive-away hesitation, loss of RPM on deceleration, difficulty starting, and/or idle RPM less than desired. Malfunction indicator lamp (MIL) may be illuminated with diagnostic trouble codes (DTCs) P0506 and/or P0505. These conditions may appear after battery disconnect, dead battery condition, or keep alive memory (KAM) reset. The symptoms may be due to engine deposits in the throttle leading to air[low less than desired. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 53.9 and higher or 54.1 and higher. This new calibration is not included in the VCM 2008.1 DVD. Calibration files may also be obtained at the website. The calibration contains a sludge compensation strategy for the throttle body. 2. Turn the key off to re-initialize the PCM. This will allow the sludge compensation strategy to learn. 3. With the vehicle in park or neutral and A/C off, start vehicle and allow engine to reach normal operating temperature(greater than 170 °F (77 °C) coolant temperature). Run an additional 5 minutes to allow sufficient learning time. 4. While the engine is running, using IDS datalogger or equivalent, check the PID value of ETC_TRIM. a. If ETC_TRIM value is 3.5 degrees, and/or DTC PuSE is present, then replace the electronic throttle body (ETB), following Workshop Manual (WSM), Section 303-04B. b. If ETC_TRIM value is less than 3.5 degrees and DTC PuSE is not present, but driveability concerns persist, the ETB is not the likely cause of the concern and replacement is not necessary. Continue with normal PC/ED diagnostics. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start > Page 4267 NOTE VEHICLES EQUIPPED WITH A PCM AND TCM REQUIRE COORDINATED REPROGRAMMING. THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS OUTLINED BY THE IDS. FAILURE TO FOLLOW THE KEY CYCLE PROCEDURE WITHOUT WAITING FOR THE IDS PROMPTS, WILL CAUSE THE COORDINATED REPROGRAMMING TO FAIL. THE PCM WILL BE UPDATED BUT THE 1CM WILL NOT BE UPDATED AND NEW FILES WILL NOT BE INSTALLED. IT IS CRITICAL TO FOLLOW THE IDS PROMPTS. SOME VEHICLES MAY REQUIRE SEVERAL DAYS OF DRIVING FOR THE TRANSMISSION TO FULLY ADAPT. REPROGRAMMING CONCERNS/ERRORS MAY BE CAUSED BY THE DATA LINK CONNECTOR (DLC) OR VEHICLE COMMUNICATION MODULE (VCM) BECOMING DISCONNECTED, LOW BATTERIES ON THE INTEGRATED DIAGNOSTIC SYSTEM (IDS) OR THE IDS GOING INTO ANY TYPE OF SLEEP MODE, OR LOW VEHICLE BATTERY VOLTAGE. IF THERE WAS AN INTERRUPTION DURING REPROGRAMMING, MAKE SURE THE ORIGINAL IDS SESSION THAT WAS CREATED FOR THE VEHICLE IS NOT DELETED. IF THE ORIGINAL VEHICLE SESSION IS NOT USED OR DELETED BEFORE THE MODULES ARE COMPLETELY REPROGRAMMED, FURTHER REPROGRAMMING ERRORS CAN OCCUR. THE MODULE RECOVERY PROCEDURE IS NO LONGER AVAILABLE AND IT IS CRITICAL THAT MODULE SWAPPING IS NOT PERFORMED FROM VEHICLE TO VEHICLE. TO REGAIN COMMUNICATION WITH A MODULE THAT HAS BEEN ERASED DURING REPROGRAMMING, RESUME THE ORIGINAL SESSION ONCE THE IDS IS RE-BOOTED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 081802A 2004-2006 F-150 0.4 Hr. 4.6L/5.4L, 2006 Mark LT, Econoline 350/450 6.8L 2005-2006 F-Super Duty 6.8L, 2006-2007 Explorer/Mountaineer 4.0L, 2007 Explorer Sport Trac 4.0L, 2006 Mustang 4.OL, 2005-2007 Crown Victoria, Town Car, Grand Marquis: Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Authorization Decal NOT Necessary. (Do Not Use With 9926A, 12650D) 081802A 2006-2007 1.0 Hr. Explorer/Mountaineer 4.6L, 2007 Explorer Sport Trac 4.6L: Check For DICs And Reprogram The PCM And 1CM, Includes Time To Monitor ETC_Trim Value, Authorization Decal NOT Necessary. (Do Not Use With 9926A, 12650D) 081802B 2004-2006 F-150 5.4L, 0.9 Hr. 2006 Mark LT: Check For DTCs And Reprogram The PCM, Includes Time To Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start > Page 4268 Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2004-2006 F-150 4.6L: 0.8 Hr. Check For DTCs And Reprogram The PCM Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2005-2006 Econoline 6.8L: 1.1 Hrs. Check For DTCs And Reprogram The PCM Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2005-2006 F-Super Duty 0.9 Hr. 6.8L: Check For DTCs And Reprogram The PCM Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2006-2007 Explorer, 1.4 Hrs. Mountaineer 2007 Explorer Sport Trac 4.6L: Check For DTCs And Reprogram The PCM And TCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2006-2007 Explorer, 0.8 Hr. Mountaineer 2007 Explorer Sport Trac 4.0L: Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2005-2007 Crown Victoria, 0.8 Hr. Town Car, Grand Marquis: Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-18-2 > Sep > 08 > Engine Controls - MIL ON/DTC's P0505/P0506/Hard Start > Page 4269 Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) 081802B 2006 Mustang 4.0L/4.6L: 0.8 Hr. Check For DTCs And Reprogram The PCM, Includes Time To Monitor ETC_Trim Value, Replace Throttle Body, Authorization Decal Not Necessary. (Do Not Use With 9926A, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-9-5 > May > 08 > Engine Controls - Hard Start/Rough Idle After Hot Soak PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - Hard Start/Rough Idle After Hot Soak TSB 08-9-5 05/12/08 4.0L/4.6L - HARD START/ROUGH RUNNING - AFTER LONG HOT SOAK / DIP IN RPM WHEN COMING TO A STOP - BUILT ON OR BEFORE 4/212008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer ISSUE Some 2006-2008 Explorer 4dr, Mountaineer and 2007-2008 Sport Trac vehicles equipped with 4.0L or 4.6L engine and built on or before 4/2/2008 may exhibit a dip in RPM below normal idle level of 600 RPM on deceleration with no diagnostic trouble codes (DTCs) present or a hard start / rough running condition after a long hot soak. ACTION Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 54.6 and higher or 55.1. This new calibration is not included in the VCM 2008.3 DVD. Calibration files may also be obtained at the website. 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 080905A 2006-2008 0.3 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Check For DTCs And Reprogram The PCM Authorization Decal Not Required (Do Not Use With 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 07-23-2 > Nov > 07 > A/T - Delayed Engagement/Hesitation/Bump on Decel PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T - Delayed Engagement/Hesitation/Bump on Decel TSB 07-23-2 11/26/07 6R60 TRANSMISSION EQUIPPED VEHICLES ONLY - BUMP WHILE BRAKING - BELOW 10 MPH (16 KM/H), DELAYED ENGAGEMENT, HESITATION ON TIP-IN AFTER BRAKING FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer This article supersedes TSB 07-13-8 to update the Service Procedure. ISSUE Some 2006-2008 Explorer 4dr, Mountaineer and 2007-2008 Explorer Sport Trac vehicles equipped with 6R60 transmission may exhibit a bump feeling while braking to a stop less than 10 MPH (16 Km/h). Some vehicles built prior to 05/4/2006 may exhibit the following symptoms: ^ Delayed engagements into Drive from Park Neutral or Reverse. ^ Hesitation upon tip-in after braking to a stop. This fixes the bump while braking to a stop, improves the delayed engagements and reduces the incidence of tip-in hesitation while accelerating from a stop. ACTION Follow the Service Procedure steps to reprogram the transmission control module (1CM) and the powertrain control module (PCM). Some tip-in hesitation is normal on this transmission in order to provide smooth operation. This calibration update will help to improve the condition. The harsh bump while braking to a stop will be eliminated. Several days of driving may be required for the transmission to fully adapt. SERVICE PROCEDURE NOTE DO NOT ATTEMPT TO REPLACE THE MECHATRONIC UNIT. MECHATRONIC REPAIR/REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE. 1. Install IDS/PDS or equivalent and ID the vehicle. 2. Update the PCM and TCM calibration using IDS release 51.8 and higher or 52.1 and higher. Calibration files may also be obtained at the website. Since the TCM cannot be independently reprogrammed, reprogram the PCM to ensure that engine and transmission calibrations are updated to the latest level simultaneously. 3. Clear 1CM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. (3) Choose Reset KAM. (4) Then Choose 1CM. b. Using PDS: (1) Choose all Tests and Calibrations. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 07-23-2 > Nov > 07 > A/T - Delayed Engagement/Hesitation/Bump on Decel > Page 4278 (2) Scroll down the menu and Choose Reset TCM KAM. NOTE FOR PDS, RESET 1CM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE. NOTE UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. NOTE DO NOT CLEAR THE PCM KAM. 4. Verify that the transmission fluid temperature (TFT) PID is above 175° F (80°C). If it is not at 175° F (80° C), drive unit approximately 3 miles (5 Km) to reach temperature. NOTE TFT MUST BE AT 175° F (80° C) OR ABOVE BEFORE PROCEEDING TO STEP 5. 5. Drive unit to perform adaptive shift strategy learn. a. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts must occur at engine speeds between 1300-1800 RPM. b. Continue to accelerate gently to 50 MPH (80 Km/h) so that the transmission shifts into 6th gear. c. Brake gently to a complete stop and hold foot on brake for at least 15 seconds. d. Repeat Steps (a-c) a total of five (5) times. 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 072302A 2006-2008 Explorer, 0.9 Hr. Mountaineer 2007-2008 Explorer Sport Trac 4.6L 6R60 Transmission: Check DTCs, Reprogram The PCM And TCM, Includes Time To Clear KAM And Perform Road Tests (Do Not Use With 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 06-17-13 > Sep > 06 > Engine Controls - Surge/Hesitation/T/C Cycling/A/C Perf. PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Surge/Hesitation/T/C Cycling/A/C Perf. TSB 06-17-13 09/04/06 CALIBRATION UPDATE 4.0L - VARIOUS SYMPTOMS - SURGE, HESITATION, TORQUE CONVERTER CYCLING, NO UP SHIFT AFTER A FORCED DOWNSHIFT, AND POOR A/C PERFORMANCE FORD: 2006-2007 Explorer 2007 Explorer Sport Trac MERCURY: 2006-2007 Mountaineer ISSUE Some 2006-2007 Explorer 4dr/Mountaineer and 2007 Sport Trac vehicles equipped with a 4.0L engine may exhibit a surge at steady speeds, transmission torque converter clutch cycling or hanging in a lower gear after a forced downshift during cruise control operation when operated in high ambient conditions. In addition, these vehicles may exhibit a cold hesitation/surge, engine fan noise and/or varying A/C discharge temperatures "ONLY" during low vehicle speed intermittently. ACTION Reprogram the powertrain control module (PCM) to the latest calibration using IDS release B43.16 and higher or B44.8 and higher. This new calibration is not included in the B44 CD. Calibration files may also be obtained at website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061713A 2006-2007 0.4 Hr. Explorer/Mountaineer, 2007 Explorer Sport Trac 4.0L: Check Diagnostic Trouble Codes And Reprogram The PCM (Do Not Use With 12650D) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Specifications Pressure Regulating Solenoid: Specifications Solenoid Operation Chart Solenoid Operation Chart Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4291 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4292 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4293 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4294 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4295 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4296 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4297 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4298 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4299 Pressure Regulating Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4300 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4301 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4302 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4303 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4304 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4305 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4306 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4307 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4308 Pressure Regulating Solenoid: Testing and Inspection Pinpoint Tests - OSC Equipped Vehicle Special Tool(s) (Part 1) Special Tool(s) (Part 2) Shift Solenoid Pre-Diagnosis Any time an electrical connector or solenoid body is disconnected, inspect the connector for terminal condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install new as necessary. Use this shift solenoid operation information when carrying out Pinpoint Test A. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4309 Solenoid Operation Chart (Part 1) Solenoid Operation Chart (Part 2) Shift Solenoid Failure Mode Chart Failed ON or OFF due to powertrain control module (PCM) and/or vehicle wiring concerns, solenoid electrically, mechanically or hydraulically stuck ON or OFF. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4310 SSA, SSB SSC, SSD Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4311 PC A, PC B, PC C (Part 1) PC A, PC B, PC C (Part 2) PC A, PC B, PC C (Part 3) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4312 Pressure Regulating Solenoid: Service and Repair Solenoid Body Assembly Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the drain plug and drain the fluid. 3. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. Disconnect the solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the gasket should be reused. Remove the 16 transmission fluid pan screws, fluid pan and gasket. 5. Remove the transmission fluid filter. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4313 6. CAUTION: Do not damage the solenoid body connector pins. Remove the solenoid body bolts and remove the solenoid body by pulling down on the solenoid body and pushing down on the connector from the other side of the case. Installation 1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean automatic transmission fluid. 2. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur. Install the solenoid body. Tighten the bolts in sequence shown. ^ Tighten to 8 Nm (71 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4314 3. CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be damaged. NOTE: Make sure that the fluid filter seals are correctly seated on the filter. Lubricate the seals and install the transmission fluid filter. ^ Tighten to 10 Nm (89 inch lbs.) 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage, if not damaged, the gasket should be reused. Install the transmission fluid pan and gasket and loosely install the screws. 5. Tighten the screws in a crisscross sequence. ^ Tighten to 11 Nm (8 ft. lbs.) 6. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the specification. NOTE: Always install new O-ring seals on vehicle harness connector. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission connector and connect the connector. ^ Tighten to 5 Nm (44 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4315 7. Fill the transmission. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Brake Shift Interlock Actuator Removal 1. Remove the front floor console. For additional information, refer to Console. 2. Disconnect the brake shift lock actuator electrical connector. 3. Remove the screw and the brake shift lock actuator. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 4319 Installation 1. Install the brake shift lock actuator. 2. Connect the brake shift lock actuator electrical connector. 3. Install the front floor console. For additional information, refer to Console. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications Solenoid Operation Chart Solenoid Operation Chart Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4325 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4326 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4327 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4328 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4329 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4330 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4331 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4332 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4333 Shift Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4334 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4335 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4336 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4337 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4338 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4339 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4340 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4341 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4342 Shift Solenoid: Testing and Inspection Pinpoint Tests - OSC Equipped Vehicle Special Tool(s) (Part 1) Special Tool(s) (Part 2) Shift Solenoid Pre-Diagnosis Any time an electrical connector or solenoid body is disconnected, inspect the connector for terminal condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install new as necessary. Use this shift solenoid operation information when carrying out Pinpoint Test A. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4343 Solenoid Operation Chart (Part 1) Solenoid Operation Chart (Part 2) Shift Solenoid Failure Mode Chart Failed ON or OFF due to powertrain control module (PCM) and/or vehicle wiring concerns, solenoid electrically, mechanically or hydraulically stuck ON or OFF. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4344 SSA, SSB SSC, SSD Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4345 PC A, PC B, PC C (Part 1) PC A, PC B, PC C (Part 2) PC A, PC B, PC C (Part 3) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4346 Shift Solenoid: Service and Repair Solenoid Body Assembly Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the drain plug and drain the fluid. 3. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. Disconnect the solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the gasket should be reused. Remove the 16 transmission fluid pan screws, fluid pan and gasket. 5. Remove the transmission fluid filter. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4347 6. CAUTION: Do not damage the solenoid body connector pins. Remove the solenoid body bolts and remove the solenoid body by pulling down on the solenoid body and pushing down on the connector from the other side of the case. Installation 1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean automatic transmission fluid. 2. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur. Install the solenoid body. Tighten the bolts in sequence shown. ^ Tighten to 8 Nm (71 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4348 3. CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be damaged. NOTE: Make sure that the fluid filter seals are correctly seated on the filter. Lubricate the seals and install the transmission fluid filter. ^ Tighten to 10 Nm (89 inch lbs.) 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage, if not damaged, the gasket should be reused. Install the transmission fluid pan and gasket and loosely install the screws. 5. Tighten the screws in a crisscross sequence. ^ Tighten to 11 Nm (8 ft. lbs.) 6. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the specification. NOTE: Always install new O-ring seals on vehicle harness connector. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission connector and connect the connector. ^ Tighten to 5 Nm (44 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4349 7. Fill the transmission. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Solenoid Operation Chart Solenoid Operation Chart Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4355 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4356 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4357 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4358 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4359 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4360 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4361 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4362 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4363 Torque Converter Clutch Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4364 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4365 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4366 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4367 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4368 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4369 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4370 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4371 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4372 Torque Converter Clutch Solenoid: Service and Repair Solenoid Body Assembly Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the drain plug and drain the fluid. 3. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. Disconnect the solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the gasket should be reused. Remove the 16 transmission fluid pan screws, fluid pan and gasket. 5. Remove the transmission fluid filter. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4373 6. CAUTION: Do not damage the solenoid body connector pins. Remove the solenoid body bolts and remove the solenoid body by pulling down on the solenoid body and pushing down on the connector from the other side of the case. Installation 1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean automatic transmission fluid. 2. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur. Install the solenoid body. Tighten the bolts in sequence shown. ^ Tighten to 8 Nm (71 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4374 3. CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be damaged. NOTE: Make sure that the fluid filter seals are correctly seated on the filter. Lubricate the seals and install the transmission fluid filter. ^ Tighten to 10 Nm (89 inch lbs.) 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage, if not damaged, the gasket should be reused. Install the transmission fluid pan and gasket and loosely install the screws. 5. Tighten the screws in a crisscross sequence. ^ Tighten to 11 Nm (8 ft. lbs.) 6. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the specification. NOTE: Always install new O-ring seals on vehicle harness connector. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission connector and connect the connector. ^ Tighten to 5 Nm (44 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4375 7. Fill the transmission. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Specifications Pressure Regulating Solenoid: Specifications Solenoid Operation Chart Solenoid Operation Chart Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4383 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4384 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4385 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4386 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4387 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4388 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4389 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4390 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4391 Pressure Regulating Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4392 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4393 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4394 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4395 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4396 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4397 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4398 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4399 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4400 Pressure Regulating Solenoid: Testing and Inspection Pinpoint Tests - OSC Equipped Vehicle Special Tool(s) (Part 1) Special Tool(s) (Part 2) Shift Solenoid Pre-Diagnosis Any time an electrical connector or solenoid body is disconnected, inspect the connector for terminal condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install new as necessary. Use this shift solenoid operation information when carrying out Pinpoint Test A. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4401 Solenoid Operation Chart (Part 1) Solenoid Operation Chart (Part 2) Shift Solenoid Failure Mode Chart Failed ON or OFF due to powertrain control module (PCM) and/or vehicle wiring concerns, solenoid electrically, mechanically or hydraulically stuck ON or OFF. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4402 SSA, SSB SSC, SSD Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4403 PC A, PC B, PC C (Part 1) PC A, PC B, PC C (Part 2) PC A, PC B, PC C (Part 3) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4404 Pressure Regulating Solenoid: Service and Repair Solenoid Body Assembly Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the drain plug and drain the fluid. 3. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. Disconnect the solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the gasket should be reused. Remove the 16 transmission fluid pan screws, fluid pan and gasket. 5. Remove the transmission fluid filter. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4405 6. CAUTION: Do not damage the solenoid body connector pins. Remove the solenoid body bolts and remove the solenoid body by pulling down on the solenoid body and pushing down on the connector from the other side of the case. Installation 1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean automatic transmission fluid. 2. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur. Install the solenoid body. Tighten the bolts in sequence shown. ^ Tighten to 8 Nm (71 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4406 3. CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be damaged. NOTE: Make sure that the fluid filter seals are correctly seated on the filter. Lubricate the seals and install the transmission fluid filter. ^ Tighten to 10 Nm (89 inch lbs.) 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage, if not damaged, the gasket should be reused. Install the transmission fluid pan and gasket and loosely install the screws. 5. Tighten the screws in a crisscross sequence. ^ Tighten to 11 Nm (8 ft. lbs.) 6. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the specification. NOTE: Always install new O-ring seals on vehicle harness connector. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission connector and connect the connector. ^ Tighten to 5 Nm (44 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4407 7. Fill the transmission. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Brake Shift Interlock Actuator Removal 1. Remove the front floor console. For additional information, refer to Console. 2. Disconnect the brake shift lock actuator electrical connector. 3. Remove the screw and the brake shift lock actuator. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 4411 Installation 1. Install the brake shift lock actuator. 2. Connect the brake shift lock actuator electrical connector. 3. Install the front floor console. For additional information, refer to Console. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications Solenoid Operation Chart Solenoid Operation Chart Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4417 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4418 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4419 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4420 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4421 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4422 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4423 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4424 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4425 Shift Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4426 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4427 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4428 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4429 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4430 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4431 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4432 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4433 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4434 Shift Solenoid: Testing and Inspection Pinpoint Tests - OSC Equipped Vehicle Special Tool(s) (Part 1) Special Tool(s) (Part 2) Shift Solenoid Pre-Diagnosis Any time an electrical connector or solenoid body is disconnected, inspect the connector for terminal condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install new as necessary. Use this shift solenoid operation information when carrying out Pinpoint Test A. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4435 Solenoid Operation Chart (Part 1) Solenoid Operation Chart (Part 2) Shift Solenoid Failure Mode Chart Failed ON or OFF due to powertrain control module (PCM) and/or vehicle wiring concerns, solenoid electrically, mechanically or hydraulically stuck ON or OFF. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4436 SSA, SSB SSC, SSD Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4437 PC A, PC B, PC C (Part 1) PC A, PC B, PC C (Part 2) PC A, PC B, PC C (Part 3) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4438 Shift Solenoid: Service and Repair Solenoid Body Assembly Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the drain plug and drain the fluid. 3. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. Disconnect the solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the gasket should be reused. Remove the 16 transmission fluid pan screws, fluid pan and gasket. 5. Remove the transmission fluid filter. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4439 6. CAUTION: Do not damage the solenoid body connector pins. Remove the solenoid body bolts and remove the solenoid body by pulling down on the solenoid body and pushing down on the connector from the other side of the case. Installation 1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean automatic transmission fluid. 2. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur. Install the solenoid body. Tighten the bolts in sequence shown. ^ Tighten to 8 Nm (71 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4440 3. CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be damaged. NOTE: Make sure that the fluid filter seals are correctly seated on the filter. Lubricate the seals and install the transmission fluid filter. ^ Tighten to 10 Nm (89 inch lbs.) 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage, if not damaged, the gasket should be reused. Install the transmission fluid pan and gasket and loosely install the screws. 5. Tighten the screws in a crisscross sequence. ^ Tighten to 11 Nm (8 ft. lbs.) 6. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the specification. NOTE: Always install new O-ring seals on vehicle harness connector. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission connector and connect the connector. ^ Tighten to 5 Nm (44 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4441 7. Fill the transmission. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Solenoid Operation Chart Solenoid Operation Chart Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4447 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4448 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4449 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4450 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4451 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4452 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4453 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4454 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4455 Torque Converter Clutch Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4456 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4457 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4458 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4459 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4460 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4461 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4462 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4463 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4464 Torque Converter Clutch Solenoid: Service and Repair Solenoid Body Assembly Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the drain plug and drain the fluid. 3. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. Disconnect the solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the gasket should be reused. Remove the 16 transmission fluid pan screws, fluid pan and gasket. 5. Remove the transmission fluid filter. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4465 6. CAUTION: Do not damage the solenoid body connector pins. Remove the solenoid body bolts and remove the solenoid body by pulling down on the solenoid body and pushing down on the connector from the other side of the case. Installation 1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean automatic transmission fluid. 2. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur. Install the solenoid body. Tighten the bolts in sequence shown. ^ Tighten to 8 Nm (71 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4466 3. CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be damaged. NOTE: Make sure that the fluid filter seals are correctly seated on the filter. Lubricate the seals and install the transmission fluid filter. ^ Tighten to 10 Nm (89 inch lbs.) 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage, if not damaged, the gasket should be reused. Install the transmission fluid pan and gasket and loosely install the screws. 5. Tighten the screws in a crisscross sequence. ^ Tighten to 11 Nm (8 ft. lbs.) 6. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the specification. NOTE: Always install new O-ring seals on vehicle harness connector. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission connector and connect the connector. ^ Tighten to 5 Nm (44 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4467 7. Fill the transmission. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications > Band Adjustment and Torque Chart Band: Specifications Band Adjustment and Torque Chart Band Adjustment and Torque Chart Band Adjustment and Torque Chart Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications > Band Adjustment and Torque Chart > Page 4472 Band: Specifications Band and Clutch Application Chart A Band and Clutch Application Chart A Band and Clutch Application Chart A Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications > Band Adjustment and Torque Chart > Page 4473 Band: Specifications Band and Clutch Application Chart B Band and Clutch Application Chart B Band and Clutch Application Chart B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set Band Apply Servo: Customer Interest A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set TSB 09-12-12 06/29/09 5R555/5R55N/5R55W TRANSMISSIONS - SHIFT CONCERNS, LOSS OF 2ND, 3RD AND 5TH GEAR, INCORRECT RATIO DTC'S - PROCEDURE TO INSPECT AND REPAIR SERVO PIN BORE WEAR FORD: 2002-2005 Thunderbird 2005-2009 Mustang 2002-2009 Explorer 2007-2009 Explorer Sport Trac LINCOLN: 2002-2006 Lincoln LS 2003-2005 Aviator MERCURY: 2002-2009 Mountaineer ISSUE Some 2002-2009 Explorer, Mountaineer, 2007-2009 Explorer Sport Trac, 2002-2006 Lincoln LS, 2005-2009 Mustang, 2002-2005 Thunderbird and 2003-2005 Aviator vehicles equipped with a 5R55S, 5R55W, and 5R55N transmission may experience shifting concerns. A loss of 2nd, 3rd and 5th gear, may have overdrive band or intermediate band failures due to servo pin case bore wear causing reduced apply pressure. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE For transmissions that have been determined to require an overhaul or rebuild and the overdrive band or intermediate band have excessive wear or burned/damaged band friction material, the cause maybe excessive servo pin case bore wear generally found on higher mileage vehicles, usually accompanied with incorrect ratio diagnostic trouble codes (DTCs), condition becomes worse when hot. (Figure 1) In our instructions, when we refer to the overdrive bore, we are talking about the smaller bore located closest to the bell housing. When we refer to the intermediate bore, we are talking about the larger bore located next to the line pressure tap. Inspect and repair the worn-damaged transmission case servo pin bore utilizing the Rotunda Tool 5RW Master Kit part number NRL5RW servo pin bore repair system (1-800-768-8632 option 6). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4482 1. Install the drill jig into the case by setting the jig into the case servo bore. Retain the jig in the case with the servo's snap-ring. (Figure 2) 2. Drop the 9/16" guide into the jig. It doesn't matter which one of the lands on the guide you use, as long as one of the lands is under the 3/8" Allen screw. NOTE CUTTING OIL MUST BE USED FOR LUBRICATION. THE USE OF SUBSTITUTES, PARTICULARLY ATF, MAY RESULT IN AN OVER-SIZED BORE. 3. Ream out the bore using the 9/16" reamer applying ample lubrication. NOTE DO NOT REAM ABOVE 500 RPM. (Figure 3) 4. Replace the 9/16" reamer guide with the 5/8" guide, and the 9/16" reamer with the 5/8" reamer. 5. Ream the bore out using the 5/8" reamer with ample lubrication. Take care not to either push too hard on the reamer or turn the reamer faster than 500 RPM when reaming. Either one can overly enlarge the bore, causing a loose bushing. 6. Clean the case before proceeding to Step 7. This kit utilizes two different bushings. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4483 a. The shorter bushing is for the intermediate servo and is identified by a flat ground in the bushing's hat. (Figure 4A) b. Overdrive servo bushing. (Figure 4B) c. Both bushings are chamfered and need to be installed with the recessed edge up (away from the valve body). 7. Apply Loctite® 680 Retaining Compound or equivalent to the outside of the bushing and drive the bushing in by hitting the driver until the bushing bottoms. (Figure 5) The 5RW kit uses a smaller diameter installation tool identified by a groove cut in the handle. 8. After installing the bushing, using a 15/64" bit, drill a hole in the side of the bushing by following the servo apply holes in the case 5R555 case shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4484 a. Overdrive servo. (Figure 6) b. Intermediate servo. (Figure 7) NOTE FAILURE TO PERFORM CROSS DRILL STEP IN THE NEW BUSHING WILL RESULT IN A NO SHIFT CONDITION. 9. Insert the provided sizing pin into the bore. It maybe necessary to start the pin in the bushing with a rubber mallet. Once the pin is inside the bushing, use a punch to drive the pin all the way through the bushing. Repeat as necessary. (Figure 8) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4485 Correctly installed bushings will be flush inside of case. (Figure 9) The 9/16" and 5/8" reamers require typical maintenance and cleaning of aluminum build up on the cutting edges to help provide optimum bushing installation and increased tool life. After bushing installation, thoroughly wash the case before rebuilding transmission. WARRANTY STATUS: Information Only Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set Band Apply Servo: All Technical Service Bulletins A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set TSB 09-12-12 06/29/09 5R555/5R55N/5R55W TRANSMISSIONS - SHIFT CONCERNS, LOSS OF 2ND, 3RD AND 5TH GEAR, INCORRECT RATIO DTC'S - PROCEDURE TO INSPECT AND REPAIR SERVO PIN BORE WEAR FORD: 2002-2005 Thunderbird 2005-2009 Mustang 2002-2009 Explorer 2007-2009 Explorer Sport Trac LINCOLN: 2002-2006 Lincoln LS 2003-2005 Aviator MERCURY: 2002-2009 Mountaineer ISSUE Some 2002-2009 Explorer, Mountaineer, 2007-2009 Explorer Sport Trac, 2002-2006 Lincoln LS, 2005-2009 Mustang, 2002-2005 Thunderbird and 2003-2005 Aviator vehicles equipped with a 5R55S, 5R55W, and 5R55N transmission may experience shifting concerns. A loss of 2nd, 3rd and 5th gear, may have overdrive band or intermediate band failures due to servo pin case bore wear causing reduced apply pressure. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE For transmissions that have been determined to require an overhaul or rebuild and the overdrive band or intermediate band have excessive wear or burned/damaged band friction material, the cause maybe excessive servo pin case bore wear generally found on higher mileage vehicles, usually accompanied with incorrect ratio diagnostic trouble codes (DTCs), condition becomes worse when hot. (Figure 1) In our instructions, when we refer to the overdrive bore, we are talking about the smaller bore located closest to the bell housing. When we refer to the intermediate bore, we are talking about the larger bore located next to the line pressure tap. Inspect and repair the worn-damaged transmission case servo pin bore utilizing the Rotunda Tool 5RW Master Kit part number NRL5RW servo pin bore repair system (1-800-768-8632 option 6). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4491 1. Install the drill jig into the case by setting the jig into the case servo bore. Retain the jig in the case with the servo's snap-ring. (Figure 2) 2. Drop the 9/16" guide into the jig. It doesn't matter which one of the lands on the guide you use, as long as one of the lands is under the 3/8" Allen screw. NOTE CUTTING OIL MUST BE USED FOR LUBRICATION. THE USE OF SUBSTITUTES, PARTICULARLY ATF, MAY RESULT IN AN OVER-SIZED BORE. 3. Ream out the bore using the 9/16" reamer applying ample lubrication. NOTE DO NOT REAM ABOVE 500 RPM. (Figure 3) 4. Replace the 9/16" reamer guide with the 5/8" guide, and the 9/16" reamer with the 5/8" reamer. 5. Ream the bore out using the 5/8" reamer with ample lubrication. Take care not to either push too hard on the reamer or turn the reamer faster than 500 RPM when reaming. Either one can overly enlarge the bore, causing a loose bushing. 6. Clean the case before proceeding to Step 7. This kit utilizes two different bushings. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4492 a. The shorter bushing is for the intermediate servo and is identified by a flat ground in the bushing's hat. (Figure 4A) b. Overdrive servo bushing. (Figure 4B) c. Both bushings are chamfered and need to be installed with the recessed edge up (away from the valve body). 7. Apply Loctite® 680 Retaining Compound or equivalent to the outside of the bushing and drive the bushing in by hitting the driver until the bushing bottoms. (Figure 5) The 5RW kit uses a smaller diameter installation tool identified by a groove cut in the handle. 8. After installing the bushing, using a 15/64" bit, drill a hole in the side of the bushing by following the servo apply holes in the case 5R555 case shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4493 a. Overdrive servo. (Figure 6) b. Intermediate servo. (Figure 7) NOTE FAILURE TO PERFORM CROSS DRILL STEP IN THE NEW BUSHING WILL RESULT IN A NO SHIFT CONDITION. 9. Insert the provided sizing pin into the bore. It maybe necessary to start the pin in the bushing with a rubber mallet. Once the pin is inside the bushing, use a punch to drive the pin all the way through the bushing. Repeat as necessary. (Figure 8) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4494 Correctly installed bushings will be flush inside of case. (Figure 9) The 9/16" and 5/8" reamers require typical maintenance and cleaning of aluminum build up on the cutting edges to help provide optimum bushing installation and increased tool life. After bushing installation, thoroughly wash the case before rebuilding transmission. WARRANTY STATUS: Information Only Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions Brake Switch - TCC: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4499 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4500 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4501 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4502 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4503 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4504 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4505 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4506 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4507 Brake Switch - TCC: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4508 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4509 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4510 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4511 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4512 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4513 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4514 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4515 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams > Page 4516 Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Customer Interest for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set Case: Customer Interest A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set TSB 09-12-12 06/29/09 5R555/5R55N/5R55W TRANSMISSIONS - SHIFT CONCERNS, LOSS OF 2ND, 3RD AND 5TH GEAR, INCORRECT RATIO DTC'S - PROCEDURE TO INSPECT AND REPAIR SERVO PIN BORE WEAR FORD: 2002-2005 Thunderbird 2005-2009 Mustang 2002-2009 Explorer 2007-2009 Explorer Sport Trac LINCOLN: 2002-2006 Lincoln LS 2003-2005 Aviator MERCURY: 2002-2009 Mountaineer ISSUE Some 2002-2009 Explorer, Mountaineer, 2007-2009 Explorer Sport Trac, 2002-2006 Lincoln LS, 2005-2009 Mustang, 2002-2005 Thunderbird and 2003-2005 Aviator vehicles equipped with a 5R55S, 5R55W, and 5R55N transmission may experience shifting concerns. A loss of 2nd, 3rd and 5th gear, may have overdrive band or intermediate band failures due to servo pin case bore wear causing reduced apply pressure. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE For transmissions that have been determined to require an overhaul or rebuild and the overdrive band or intermediate band have excessive wear or burned/damaged band friction material, the cause maybe excessive servo pin case bore wear generally found on higher mileage vehicles, usually accompanied with incorrect ratio diagnostic trouble codes (DTCs), condition becomes worse when hot. (Figure 1) In our instructions, when we refer to the overdrive bore, we are talking about the smaller bore located closest to the bell housing. When we refer to the intermediate bore, we are talking about the larger bore located next to the line pressure tap. Inspect and repair the worn-damaged transmission case servo pin bore utilizing the Rotunda Tool 5RW Master Kit part number NRL5RW servo pin bore repair system (1-800-768-8632 option 6). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Customer Interest for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4525 1. Install the drill jig into the case by setting the jig into the case servo bore. Retain the jig in the case with the servo's snap-ring. (Figure 2) 2. Drop the 9/16" guide into the jig. It doesn't matter which one of the lands on the guide you use, as long as one of the lands is under the 3/8" Allen screw. NOTE CUTTING OIL MUST BE USED FOR LUBRICATION. THE USE OF SUBSTITUTES, PARTICULARLY ATF, MAY RESULT IN AN OVER-SIZED BORE. 3. Ream out the bore using the 9/16" reamer applying ample lubrication. NOTE DO NOT REAM ABOVE 500 RPM. (Figure 3) 4. Replace the 9/16" reamer guide with the 5/8" guide, and the 9/16" reamer with the 5/8" reamer. 5. Ream the bore out using the 5/8" reamer with ample lubrication. Take care not to either push too hard on the reamer or turn the reamer faster than 500 RPM when reaming. Either one can overly enlarge the bore, causing a loose bushing. 6. Clean the case before proceeding to Step 7. This kit utilizes two different bushings. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Customer Interest for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4526 a. The shorter bushing is for the intermediate servo and is identified by a flat ground in the bushing's hat. (Figure 4A) b. Overdrive servo bushing. (Figure 4B) c. Both bushings are chamfered and need to be installed with the recessed edge up (away from the valve body). 7. Apply Loctite® 680 Retaining Compound or equivalent to the outside of the bushing and drive the bushing in by hitting the driver until the bushing bottoms. (Figure 5) The 5RW kit uses a smaller diameter installation tool identified by a groove cut in the handle. 8. After installing the bushing, using a 15/64" bit, drill a hole in the side of the bushing by following the servo apply holes in the case 5R555 case shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Customer Interest for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4527 a. Overdrive servo. (Figure 6) b. Intermediate servo. (Figure 7) NOTE FAILURE TO PERFORM CROSS DRILL STEP IN THE NEW BUSHING WILL RESULT IN A NO SHIFT CONDITION. 9. Insert the provided sizing pin into the bore. It maybe necessary to start the pin in the bushing with a rubber mallet. Once the pin is inside the bushing, use a punch to drive the pin all the way through the bushing. Repeat as necessary. (Figure 8) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Customer Interest for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4528 Correctly installed bushings will be flush inside of case. (Figure 9) The 9/16" and 5/8" reamers require typical maintenance and cleaning of aluminum build up on the cutting edges to help provide optimum bushing installation and increased tool life. After bushing installation, thoroughly wash the case before rebuilding transmission. WARRANTY STATUS: Information Only Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set Case: All Technical Service Bulletins A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set TSB 09-12-12 06/29/09 5R555/5R55N/5R55W TRANSMISSIONS - SHIFT CONCERNS, LOSS OF 2ND, 3RD AND 5TH GEAR, INCORRECT RATIO DTC'S - PROCEDURE TO INSPECT AND REPAIR SERVO PIN BORE WEAR FORD: 2002-2005 Thunderbird 2005-2009 Mustang 2002-2009 Explorer 2007-2009 Explorer Sport Trac LINCOLN: 2002-2006 Lincoln LS 2003-2005 Aviator MERCURY: 2002-2009 Mountaineer ISSUE Some 2002-2009 Explorer, Mountaineer, 2007-2009 Explorer Sport Trac, 2002-2006 Lincoln LS, 2005-2009 Mustang, 2002-2005 Thunderbird and 2003-2005 Aviator vehicles equipped with a 5R55S, 5R55W, and 5R55N transmission may experience shifting concerns. A loss of 2nd, 3rd and 5th gear, may have overdrive band or intermediate band failures due to servo pin case bore wear causing reduced apply pressure. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE For transmissions that have been determined to require an overhaul or rebuild and the overdrive band or intermediate band have excessive wear or burned/damaged band friction material, the cause maybe excessive servo pin case bore wear generally found on higher mileage vehicles, usually accompanied with incorrect ratio diagnostic trouble codes (DTCs), condition becomes worse when hot. (Figure 1) In our instructions, when we refer to the overdrive bore, we are talking about the smaller bore located closest to the bell housing. When we refer to the intermediate bore, we are talking about the larger bore located next to the line pressure tap. Inspect and repair the worn-damaged transmission case servo pin bore utilizing the Rotunda Tool 5RW Master Kit part number NRL5RW servo pin bore repair system (1-800-768-8632 option 6). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4534 1. Install the drill jig into the case by setting the jig into the case servo bore. Retain the jig in the case with the servo's snap-ring. (Figure 2) 2. Drop the 9/16" guide into the jig. It doesn't matter which one of the lands on the guide you use, as long as one of the lands is under the 3/8" Allen screw. NOTE CUTTING OIL MUST BE USED FOR LUBRICATION. THE USE OF SUBSTITUTES, PARTICULARLY ATF, MAY RESULT IN AN OVER-SIZED BORE. 3. Ream out the bore using the 9/16" reamer applying ample lubrication. NOTE DO NOT REAM ABOVE 500 RPM. (Figure 3) 4. Replace the 9/16" reamer guide with the 5/8" guide, and the 9/16" reamer with the 5/8" reamer. 5. Ream the bore out using the 5/8" reamer with ample lubrication. Take care not to either push too hard on the reamer or turn the reamer faster than 500 RPM when reaming. Either one can overly enlarge the bore, causing a loose bushing. 6. Clean the case before proceeding to Step 7. This kit utilizes two different bushings. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4535 a. The shorter bushing is for the intermediate servo and is identified by a flat ground in the bushing's hat. (Figure 4A) b. Overdrive servo bushing. (Figure 4B) c. Both bushings are chamfered and need to be installed with the recessed edge up (away from the valve body). 7. Apply Loctite® 680 Retaining Compound or equivalent to the outside of the bushing and drive the bushing in by hitting the driver until the bushing bottoms. (Figure 5) The 5RW kit uses a smaller diameter installation tool identified by a groove cut in the handle. 8. After installing the bushing, using a 15/64" bit, drill a hole in the side of the bushing by following the servo apply holes in the case 5R555 case shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4536 a. Overdrive servo. (Figure 6) b. Intermediate servo. (Figure 7) NOTE FAILURE TO PERFORM CROSS DRILL STEP IN THE NEW BUSHING WILL RESULT IN A NO SHIFT CONDITION. 9. Insert the provided sizing pin into the bore. It maybe necessary to start the pin in the bushing with a rubber mallet. Once the pin is inside the bushing, use a punch to drive the pin all the way through the bushing. Repeat as necessary. (Figure 8) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4537 Correctly installed bushings will be flush inside of case. (Figure 9) The 9/16" and 5/8" reamers require typical maintenance and cleaning of aluminum build up on the cutting edges to help provide optimum bushing installation and increased tool life. After bushing installation, thoroughly wash the case before rebuilding transmission. WARRANTY STATUS: Information Only Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T 'Wrench Lamp' ON/Multiple DTC's Set In TCM Control Module: Customer Interest A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM TSB 07-6-3 04/02/07 6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac MERCURY: 2006-2007 Mountaineer ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition vehicles may exhibit the following diagnostic trouble codes in the transmission control module (1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657, P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083, P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination at the mechatronic assembly. ACTION Follow the Service Procedure steps to correct the condition. NOTE IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM BARRIER STRIP. SERVICE PROCEDURE Remove the source of contamination from the transmission control unit (TCU)/solenoid connections and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent recurrence. 1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01. 2. Remove the six (6) long fasteners from the TCM unit. (Figure 1) 3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of the main control during this procedure. NOTE IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS SYSTEM. 4. Inspect the TCM at the following locations for metal chips or other metallic contamination. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4546 a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination. (Figure 2) b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure 3 and 4) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4547 c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure 5) 5. Prior to installation of the protective strip, remove all machining chips and or other metallic contamination from these areas with a clean, lint free cloth. 6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam barrier strip is installed). 7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first, "point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM, Section 307-01. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4548 8. Reinstall the mechatronic assembly following the WSM, Section 307-01. 9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01. 10. Set the transmission fluid level following the WSM, Section 307-01. 11. Clear all DTC(s) from the TCM. 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 070603A 2006-2007 2.6 Hrs. Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) 070603A 2007 Expedition 6R75 2.7 Hrs. Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) DEALER CODING CONDITION BASIC PART NO. CODE 14B167 49 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM Control Module: All Technical Service Bulletins A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM TSB 07-6-3 04/02/07 6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac MERCURY: 2006-2007 Mountaineer ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition vehicles may exhibit the following diagnostic trouble codes in the transmission control module (1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657, P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083, P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination at the mechatronic assembly. ACTION Follow the Service Procedure steps to correct the condition. NOTE IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM BARRIER STRIP. SERVICE PROCEDURE Remove the source of contamination from the transmission control unit (TCU)/solenoid connections and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent recurrence. 1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01. 2. Remove the six (6) long fasteners from the TCM unit. (Figure 1) 3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of the main control during this procedure. NOTE IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS SYSTEM. 4. Inspect the TCM at the following locations for metal chips or other metallic contamination. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4554 a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination. (Figure 2) b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure 3 and 4) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4555 c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure 5) 5. Prior to installation of the protective strip, remove all machining chips and or other metallic contamination from these areas with a clean, lint free cloth. 6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam barrier strip is installed). 7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first, "point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM, Section 307-01. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4556 8. Reinstall the mechatronic assembly following the WSM, Section 307-01. 9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01. 10. Set the transmission fluid level following the WSM, Section 307-01. 11. Clear all DTC(s) from the TCM. 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 070603A 2006-2007 2.6 Hrs. Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) 070603A 2007 Expedition 6R75 2.7 Hrs. Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) DEALER CODING CONDITION BASIC PART NO. CODE 14B167 49 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid 5R55S .................................................................................................................. ......................................................................................... 13.0 qts (12.3L) 6R60 ................................ .............................................................................................................................................................. ............... 12.2 qts (11.6L) Note: Indicates only approximate dry-fill capacity. Some applications may vary based on cooler size and if equipped with an in-tank cooler. The amount of transmission fluid and fluid level should be checked by a qualified technician Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 4561 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type 5R55S .................................................................................................................................................. ............................................................. MERCON V 6R60 .................................................................. .............................................................................................................................................. MERCON SP Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Level Check Fluid - A/T: Service and Repair Transmission Fluid Level Check Transmission Fluid Level Check Special Tool(s) Material NOTE: Left side of case shown. Fluid Fill Reference NOTE: Left side of case shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Level Check > Page 4564 Fluid Fill Reference 1. Using the scan tool, monitor the transmission fluid temperature (TFT) using PID: TFT. 2. Start the vehicle. 3. NOTE: Engine idle speed is approximately 650 rpm. While proceeding with this procedure, run the engine until the transmission fluid temperature is between 27 - 49°C (80 - 120°F). 4. Move the range selector lever slowly through each gear, stopping in each position and allowing the transmission to engage. 5. Place the range selector lever in the PARK position. 6. With the engine running and the vehicle set as close to level as possible, position it on a hoist. For additional information, refer to Maintenance /Service and Repair. 7. Hold the larger drain plug with a wrench and remove the small (center) fluid level indicating plug. 8. Install the special tool into the pan. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Level Check > Page 4565 9. NOTE: Prior to filling the special tool with clean transmission fluid, make sure that the canister is clean. Fill the special tool with clean automatic transmission fluid. 10. Hang the special tool under the vehicle. Position it upright and close to the transmission. 11. Connect the special tools. ^ Connect the open end of the fluid hose from the Fluid Transporter/Evacuator/Injector to the Fluid Level and Fill Plug Adapter at the bottom of the transmission fluid pan. 12. Apply a maximum of 206.85 kPa (30 psi) to the open end of the vacuum/pressure hose from the special tool. Fluid will immediately start flowing out of the special tool into the transmission fluid pan. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Level Check > Page 4566 13. Add 0.5L (1 pt) of transmission fluid into the fluid pan. Stop the process by releasing the air pressure and removing the air nozzle from the end of the hose. 14. Inspect the fluid level in the special tool. If the fluid drains back into the canister, the transmission is full. If no fluid drains back, more fluid will need to be added. Repeat Steps 12 and 13. 15. Once the transmission is full, place a hand vacuum pump on the open end of the vacuum/pressure hose on the special tool and apply vacuum to the system. This will pull out any extra fluid trapped in the system and direct it into the container. 16. Allow the fluid to drain. Make sure that the fluid temperature is between 27 - 49°C (80 - 120°F). When the fluid comes out as a thin stream or drip, the fluid is at the correct level. 17. Reinstall the small (center) fluid level indicating plug using a 3/16-inch Allen key. ^ Tighten to 10 Nm (89 inch lbs.) 18. Check the operation of the transmission by moving the range selector lever slowly through each gear, stopping in each position and allowing the transmission to engage. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Level Check > Page 4567 Fluid - A/T: Service and Repair Transmission Fluid Drain and Refill - Automated Equipment Transmission Fluid Drain and Refill - Automated Equipment Special Tool(s) Material Draining CAUTION: Do not use water-based cleaners, mineral spirits, brake cleaner or solvents that may contain acetone, xylene or heptane to clean and/or flush the transmission assembly, transmission components and the torque converter or transmission damage will occur. Use only clean transmission fluid designated for the transmission/converter being serviced. CAUTION: Always refer to the instructions supplied with the flush and fill machine. 1. With the vehicle in PARK, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 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 line. This will help remove any foreign material trapped in the fluid coolers. 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. With the engine running, check and adjust the transmission fluid level and check for any leaks. If fluid is needed, add fluid in increments of 0.24L (0.5 pt) until the correct level is achieved. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Level Check > Page 4568 Fluid - A/T: Service and Repair Transmission Fluid Drain and Refill - Without Torque Converter Drain Plug Transmission Fluid Drain and Refill - Without Torque Converter Drain Plug Special Tool(s) Material Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Level Check > Page 4569 Fluid Fill Reference Draining 1. With the vehicle in PARK, position it on a hoist. Set the vehicle as close to level as possible. For additional information, refer to Maintenance /Service and Repair. 2. Remove the drain plug (large plug) and allow the fluid to drain. Refill 1. Install the fluid drain plug. ^ Tighten to 26 Nm (19 ft. lbs.) 2. Hold the larger drain plug with a wrench and remove the small (center) fluid level indicating plug. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Level Check > Page 4570 3. Install the special tool into the pan. 4. NOTE: Prior to filling the special tool with clean transmission fluid, make sure that the canister is clean. Fill the special tool with clean automatic transmission fluid. 5. Hang the special tool under the vehicle, upright and close to the transmission. 6. Connect the special tools. ^ Connect the open end of the fluid hose from the Fluid Transporter/Evacuator/Injector to the Fluid Level and Fill Plug Adapter at the bottom of the transmission fluid pan. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Level Check > Page 4571 7. Apply a maximum of 206.85 kPa (30 psi) to the open end of the vacuum/pressure hose from the special tool. Fluid will immediately start flowing out of the special tool into the transmission fluid pan. 8. Add 1.89L or 2.83L (2 qt or 3 qt) of transmission fluid into the fluid pan. Stop the process by releasing the air pressure and removing the air nozzle from the end of the hose. 9. NOTE: Engine idle speed is approximately 650 rpm. Using the scan tool, start and run the engine until the transmission fluid temperature is between 27°C - 49°C (80°F - 120°F). 10. Inspect the fluid level in the special tool. If the fluid drains back into the canister, the transmission is full. If no fluid drains back, more fluid will need to be added. Repeat Steps 9 and 10. 11. Once the transmission is full, place a hand vacuum pump on the open end of the vacuum/pressure hose on the special tool and apply vacuum to the system. This will pull out any extra fluid trapped in the system and direct it into the container. 12. Allow the fluid to drain. When the fluid comes out as a thin stream or drip, the fluid is at the correct level. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Level Check > Page 4572 13. Reinstall the small (center) fluid level indicating plug. ^ Tighten to 10 Nm (89 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Transmission Fluid Level Check > Page 4573 Fluid - A/T: Service and Repair Transmission Fluid Cooler - Backflushing and Cleaning Transmission Fluid Cooler - Backflushing and Cleaning Material CAUTION: Whenever a transmission has been disassembled to install new parts or a new or remanufactured transmission has been installed, a new transmission fluid cooler, either in-tank, auxiliary or oil to air (OTA), if equipped will need to be installed. Using a suitable torque converter/fluid cooler cleaner, clean and backflush the transmission fluid cooler tubes. CAUTION: Do not use water-based cleaners, mineral spirits, brake cleaner or solvents that may contain acetone, xylene or heptane to clean and/or flush the transmission assembly, transmission components and the torque converter or transmission damage will occur. Use only clean transmission fluid designated for the transmission/converter being serviced. When internal wear or damage has occurred in the transmission, metal particles, clutch plate material or band material may have been carried into the transmission fluid cooler. These contaminants are a major cause of recurring transmission concerns and must be removed from the system before the transmission is put back in use. 1. Conduct backflushing with a suitable torque converter/transmission fluid cooler cleaner. Test the equipment to make sure that a vigorous fluid flow is present before proceeding. Install a new system filter if flow is weak or contaminated. 2. Remove and discard the in-line transmission fluid filter, if equipped. 3. To aid in attaching the cleaner to the transmission steel cooler lines, connect 2 additional rubber hoses to the transmission end of the steel transmission cooler lines as described. ^ Connect the cleaner tank pressure line to the steel transmission cooler return line (longest line). ^ Connect a tank return hose to the steel transmission cooler pressure line (shorter line). Place the outlet end of this hose in the solvent tank reservoir. 4. Turn on the pump and allow the transmission fluid to circulate a minimum of 5 minutes (cycling switch on and off will help dislodge contaminants in the cooler system). 5. Switch off the pump and disconnect the pressure hose from the transmission cooler return line. 6. Use compressed air to blow out the cooler(s) and lines (blow air into the transmission cooler return line) until all the fluid is removed. 7. Remove the rubber return hose from the remaining steel cooler line. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter Fluid Filter - A/T: Service and Repair Fluid Pan, Gasket and Filter Fluid Pan, Gasket and Filter Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Place a drain pan under the transmission fluid pan. 3. Remove the drain plug and drain the fluid. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the gasket should be reused. Remove the 16 transmission fluid pan screws, fluid pan and gasket. 5. Remove and discard the transmission fluid filter. 6. Clean and inspect the transmission fluid pan and magnet. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 4578 Installation 1. CAUTION: Damage may occur to fluid filter seals if they are not lubricated with clean automatic transmission fluid. NOTE: Make sure that the fluid filter seals are correctly seated on the filter. Lubricate the seals and install the transmission fluid filter. ^ Tighten to 10 Nm (89 inch lbs.) 2. Install the fluid pan magnet in the transmission fluid pan. 3. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the gasket should be reused. Install the fluid pan gasket on the pan. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 4579 4. Install the transmission fluid pan and gasket and loosely install the screws. 5. Tighten the screws in a crisscross sequence. ^ Tighten to 11 Nm (8 ft. lbs.) 6. Install the fluid drain plug. ^ Tighten to 26 Nm (19 ft. lbs.) 7. Partially fill the transmission. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 4580 Fluid Filter - A/T: Service and Repair Transmission Filter - In Line Transmission Filter - In Line Special Tool(s) Material NOTE: Use these guidelines for installing the transmission fluid in-line filter: ^ If the transmission was overhauled and the vehicle was equipped with an in-line fluid filter, install a new in-line fluid filter. ^ If the transmission was overhauled and the vehicle was not equipped with an in-line fluid filter, install a new in-line fluid filter kit. ^ If the transmission is being installed for a non-internal repair, do not install an in-line filter or filter kit. ^ If installing a Ford-authorized remanufactured transmission, install the in-line transmission fluid filter that is supplied. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the secondary latch from the fluid cooler connector. 3. Using the special tool, disconnect the fluid cooler connector. 4. Remove the section of the steel tube at the second flare. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 4581 ^ Clean and deburr the cut end of the steel tube. 5. NOTE: Be sure the cooler tube is fully seated in the body of the fitting before final tightening of the ferrule nut. Install the tubing ferrule hose assembly connector onto the end of the steel fluid cooler tube. Finger-tighten the ferrule nut, then tighten the nut an additional 1-1/2 turns to seat the ferrule in the connector. 6. Remove the section of the rubber hose as illustrated. 7. CAUTION: The filter has a bypass valve in it. The red arrow on the filter indicates the direction of fluid flow through the filter. The filter must be installed in the fluid cooler return line with the red arrow on the filter pointing away from the transmission fluid cooler and toward the transmission (the return line has fluid coming out of the cooler going to the transmission). If the fluid filter is not installed correctly, it will cause internal transmission damage. CAUTION: Do not install any rubber hoses or steel tubing with a bend entering the filter greater than 60°. Install the one end of the filter into the rubber hose with a clamp. ^ Tighten the hose clamp. 8. Using a suitable length of hose, install the other end of the filter into the tubing ferrule hose assembly with 2 clamps. ^ Tighten the hose clamps. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 4582 9. Clean a section of the transmission fluid pan, then install the sticker. 10. Fill the transmission with clean automatic transmission fluid. ^ Verify for correct operation. ^ Check the filter for leaks. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Tubes Transmission Fluid Cooler Tubes - 5R55S Special Tool(s) Material Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 4587 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Using a backup wrench to hold the case fitting securely, disconnect the fluid cooler fittings. 3. Remove the secondary latch from the cooler tube. 4. Using the special tool, disconnect the quick connect coupler and remove the transmission fluid cooler tube from the radiator. 5. Remove the secondary latch from the transmission fluid cooler tube. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 4588 6. Using the special tool, disconnect the quick connect coupler and separate the transmission fluid cooler tube from the transmission fluid cooler hose. 7. Remove the transmission fluid cooler tube bracket nut. 8. Remove the fluid cooler tube bracket from the stud. 9. Remove the transmission cooler tubes from the vehicle. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 4589 Installation 1. Install the transmission cooler tubes into the vehicle. 2. Install the transmission fluid cooler tube bracket onto the stud. 3. Verify the case fitting torque. ^ Tighten to 56 Nm (41 ft. lbs.) 4. CAUTION: To prevent cross threading, all tube nuts must be hand started before being torqued to specification. Using a backup wrench to hold the case fittings securely, install the transmission fluid cooler tubes. ^ Tighten to 40 Nm (30 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 4590 5. Install the transmission fluid cooler tube bracket nut. ^ Tighten to 25 Nm (18 ft. lbs.) 6. Connect the transmission fluid cooler tube to the transmission fluid cooler hose. 7. Install the secondary latch. 8. Connect the transmission fluid cooler tube to the radiator. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 4591 9. Install the secondary latch. 10. Fill transmission fluid to the correct level using clean automatic transmission fluid and inspect for leaks. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 4592 Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Hoses Transmission Fluid Cooler Hoses Special Tool(s) Material Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 4593 Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. Mountaineer 2. Remove the grille fasteners and the grille. Explorer 3. Remove the bumper cover. All vehicles Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 4594 4. Remove the inner grille air deflector. 5. Push the lower air deflector down past the transmission fluid cooler. 6. Disconnect the transmission fluid cooler hoses. ^ Remove and discard the transmission fluid cooler hoses and the clamps. 7. Remove the secondary latch from the transmission fluid cooler tube. 8. Using the special tool, disconnect the quick connect coupler and separate the transmission fluid cooler tube from the transmission cooler hose. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 4595 9. Remove the secondary latch from the transmission fluid cooler hose. 10. Using the special tool, disconnect the quick connect coupler and remove the transmission fluid cooler tube from the radiator. 11. Remove the hoses from the retainer. Installation All vehicles 1. Install the hoses into the retainer. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 4596 2. Install the transmission fluid cooler hose to the radiator. 3. Install the secondary latch. 4. Install the transmission fluid cooler hose to the transmission fluid cooler tube. 5. Install the secondary latch. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 4597 6. NOTE: Clean the cooler tube stems with degreaser prior to installing the hoses. Using new hoses and clamps, install the new transmission fluid cooler hoses. 7. Push the lower air deflector back into place. 8. Install the inner grille air deflector. Mountaineer 9. Install the grille and the fasteners. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 4598 Explorer 10. Install the bumper cover. All vehicles 11. Fill the transmission fluid to the correct level using clean automatic transmission fluid and inspect for leaks. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications Transmission fluid pan screws ............................................................................................................................. 11 Nm (8 ft. lbs.) in a crisscross sequence Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 4602 Fluid Pan: Service and Repair Fluid Pan, Gasket and Filter Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Place a drain pan under the transmission fluid pan. 3. Remove the drain plug and drain the fluid. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the gasket should be reused. Remove the 16 transmission fluid pan screws, fluid pan and gasket. 5. Remove and discard the transmission fluid filter. 6. Clean and inspect the transmission fluid pan and magnet. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 4603 Installation 1. CAUTION: Damage may occur to fluid filter seals if they are not lubricated with clean automatic transmission fluid. NOTE: Make sure that the fluid filter seals are correctly seated on the filter. Lubricate the seals and install the transmission fluid filter. ^ Tighten to 10 Nm (89 inch lbs.) 2. Install the fluid pan magnet in the transmission fluid pan. 3. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the gasket should be reused. Install the fluid pan gasket on the pan. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 4604 4. Install the transmission fluid pan and gasket and loosely install the screws. 5. Tighten the screws in a crisscross sequence. ^ Tighten to 11 Nm (8 ft. lbs.) 6. Install the fluid drain plug. ^ Tighten to 26 Nm (19 ft. lbs.) 7. Partially fill the transmission. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 (TCIL) The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Overdrive Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4613 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4614 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4615 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4616 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4617 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4618 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4619 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4620 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4621 Overdrive Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4622 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4623 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4624 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4625 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4626 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4627 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4628 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4629 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Specifications Pressure Regulating Solenoid: Specifications Solenoid Operation Chart Solenoid Operation Chart Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4635 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4636 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4637 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4638 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4639 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4640 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4641 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4642 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4643 Pressure Regulating Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4644 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4645 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4646 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4647 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4648 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4649 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4650 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4651 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4652 Pressure Regulating Solenoid: Testing and Inspection Pinpoint Tests - OSC Equipped Vehicle Special Tool(s) (Part 1) Special Tool(s) (Part 2) Shift Solenoid Pre-Diagnosis Any time an electrical connector or solenoid body is disconnected, inspect the connector for terminal condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install new as necessary. Use this shift solenoid operation information when carrying out Pinpoint Test A. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4653 Solenoid Operation Chart (Part 1) Solenoid Operation Chart (Part 2) Shift Solenoid Failure Mode Chart Failed ON or OFF due to powertrain control module (PCM) and/or vehicle wiring concerns, solenoid electrically, mechanically or hydraulically stuck ON or OFF. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4654 SSA, SSB SSC, SSD Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4655 PC A, PC B, PC C (Part 1) PC A, PC B, PC C (Part 2) PC A, PC B, PC C (Part 3) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4656 Pressure Regulating Solenoid: Service and Repair Solenoid Body Assembly Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the drain plug and drain the fluid. 3. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. Disconnect the solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the gasket should be reused. Remove the 16 transmission fluid pan screws, fluid pan and gasket. 5. Remove the transmission fluid filter. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4657 6. CAUTION: Do not damage the solenoid body connector pins. Remove the solenoid body bolts and remove the solenoid body by pulling down on the solenoid body and pushing down on the connector from the other side of the case. Installation 1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean automatic transmission fluid. 2. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur. Install the solenoid body. Tighten the bolts in sequence shown. ^ Tighten to 8 Nm (71 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4658 3. CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be damaged. NOTE: Make sure that the fluid filter seals are correctly seated on the filter. Lubricate the seals and install the transmission fluid filter. ^ Tighten to 10 Nm (89 inch lbs.) 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage, if not damaged, the gasket should be reused. Install the transmission fluid pan and gasket and loosely install the screws. 5. Tighten the screws in a crisscross sequence. ^ Tighten to 11 Nm (8 ft. lbs.) 6. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the specification. NOTE: Always install new O-ring seals on vehicle harness connector. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission connector and connect the connector. ^ Tighten to 5 Nm (44 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4659 7. Fill the transmission. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM Control Module: Customer Interest A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM TSB 07-6-3 04/02/07 6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac MERCURY: 2006-2007 Mountaineer ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition vehicles may exhibit the following diagnostic trouble codes in the transmission control module (1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657, P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083, P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination at the mechatronic assembly. ACTION Follow the Service Procedure steps to correct the condition. NOTE IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM BARRIER STRIP. SERVICE PROCEDURE Remove the source of contamination from the transmission control unit (TCU)/solenoid connections and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent recurrence. 1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01. 2. Remove the six (6) long fasteners from the TCM unit. (Figure 1) 3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of the main control during this procedure. NOTE IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS SYSTEM. 4. Inspect the TCM at the following locations for metal chips or other metallic contamination. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4669 a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination. (Figure 2) b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure 3 and 4) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4670 c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure 5) 5. Prior to installation of the protective strip, remove all machining chips and or other metallic contamination from these areas with a clean, lint free cloth. 6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam barrier strip is installed). 7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first, "point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM, Section 307-01. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4671 8. Reinstall the mechatronic assembly following the WSM, Section 307-01. 9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01. 10. Set the transmission fluid level following the WSM, Section 307-01. 11. Clear all DTC(s) from the TCM. 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 070603A 2006-2007 2.6 Hrs. Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) 070603A 2007 Expedition 6R75 2.7 Hrs. Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) DEALER CODING CONDITION BASIC PART NO. CODE 14B167 49 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM Control Module: All Technical Service Bulletins A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM TSB 07-6-3 04/02/07 6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac MERCURY: 2006-2007 Mountaineer ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition vehicles may exhibit the following diagnostic trouble codes in the transmission control module (1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657, P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083, P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination at the mechatronic assembly. ACTION Follow the Service Procedure steps to correct the condition. NOTE IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM BARRIER STRIP. SERVICE PROCEDURE Remove the source of contamination from the transmission control unit (TCU)/solenoid connections and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent recurrence. 1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01. 2. Remove the six (6) long fasteners from the TCM unit. (Figure 1) 3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of the main control during this procedure. NOTE IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS SYSTEM. 4. Inspect the TCM at the following locations for metal chips or other metallic contamination. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4677 a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination. (Figure 2) b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure 3 and 4) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4678 c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure 5) 5. Prior to installation of the protective strip, remove all machining chips and or other metallic contamination from these areas with a clean, lint free cloth. 6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam barrier strip is installed). 7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first, "point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM, Section 307-01. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4679 8. Reinstall the mechatronic assembly following the WSM, Section 307-01. 9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01. 10. Set the transmission fluid level following the WSM, Section 307-01. 11. Clear all DTC(s) from the TCM. 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 070603A 2006-2007 2.6 Hrs. Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) 070603A 2007 Expedition 6R75 2.7 Hrs. Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) DEALER CODING CONDITION BASIC PART NO. CODE 14B167 49 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Gasket Seals and Gaskets: Service and Repair Extension Housing Gasket Extension Housing Gasket - Rear Wheel Drive (RWD) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the driveshaft. 3. Support the transmission with a suitable jack. 4. Remove the transmission support insulator nuts. 5. Remove the bolts from the transmission support insulator. 6. Raise the transmission and remove the transmission support insulator. 7. 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. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Gasket > Page 4684 8. Remove and discard the extension housing gasket. Installation 1. Clean the extension housing and install new extension housing gasket. Make sure that the park pawl is installed correctly. 2. CAUTION: Make sure the parking lever actuating rod is correctly seated into the case parking rod guide cup. Install the extension housing. ^ Tighten to 30 Nm (22 ft. lbs.) 3. Install the transmission support insulator and lower the transmission onto the transmission support insulator. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Gasket > Page 4685 4. Install the transmission support insulator bolts. ^ Tighten to 90 Nm (66 ft. lbs.) 5. Install the transmission support insulator nuts. ^ Tighten to 90 Nm (66 ft. lbs.) 6. Install the driveshaft. 7. Carry out fluid level check. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Gasket > Page 4686 Seals and Gaskets: Service and Repair Extension Housing Seal Extension Housing Seal - Rear Wheel Drive (RWD) Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the driveshaft. 3. Using the special tools, remove the extension housing seal. Installation 1. NOTE: Make sure the extension housing seal is correctly installed onto the special tool and the garter spring is in the correct position. Using the special tool, install the extension housing seal. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Gasket > Page 4687 2. Install the driveshaft. 3. Carry out fluid level check. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions Brake Switch - TCC: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4693 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4694 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4695 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4696 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4697 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4698 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4699 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4700 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4701 Brake Switch - TCC: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4702 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4703 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4704 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4705 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4706 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4707 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4708 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4709 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Page 4710 Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Overdrive Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4715 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4716 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4717 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4718 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4719 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4720 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4721 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4722 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4723 Overdrive Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4724 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4725 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4726 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4727 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4728 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4729 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4730 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4731 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor/Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4736 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4737 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4738 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4739 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4740 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4741 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4742 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4743 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4744 Throttle Position Sensor/Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4745 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4746 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4747 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4748 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4749 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4750 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4751 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4752 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Mode Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4757 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4758 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4759 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4760 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4761 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4762 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4763 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4764 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4765 Transmission Mode Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4766 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4767 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4768 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4769 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4770 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4771 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4772 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4773 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Control (TC) Switch Transmission Mode Switch: Description and Operation Transmission Control (TC) Switch Transmission Control (TC) Switch The transmission control (TC) switch is a momentary contact switch located on the selector lever knob. Pushing the TC switch will either disengage or engage the overdrive function of the transmission. If OVERDRIVE is disengaged, the message O/D OFF will illuminate on the instrument panel. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Control (TC) Switch > Page 4776 Transmission Mode Switch: Description and Operation Transmission Control Switch (TCS) TRANSMISSION CONTROL SWITCH (TCS) Typical Transmission Control Switch (TCS) Typical Transmission Control Switch (TCS) The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature, the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage overdrive. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Page 4777 Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch Removal 1. Remove the transmission selector lever knob. 2. Remove the transmission control switch from the knob. Installation 1. Install the transmission control switch into the knob. 2. Install the transmission selector lever knob. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4783 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4784 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4785 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4786 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4787 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4788 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4789 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4790 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4791 Transmission Position Switch/Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4792 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4793 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4794 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4795 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4796 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4797 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4798 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4799 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4800 C167 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4801 Transmission Position Switch/Sensor: Testing and Inspection Digital Transmission Range (TR) Sensor Diagnosis Chart Digital Transmission Range (TR) Sensor Diagnosis Chart Wiggle Test Information for Open/Shorts ^ TR4, TR3A, TR2 and TR1 are all closed in PARK. PARK is a good position to check for intermittent open circuits (with scan tool monitoring TRD). ^ TR4, TR3A, TR2 and TR1 are all open in OVERDRIVE, so OVERDRIVE is a good position to check for shorts to ground. To determine the shorted components while observing TRD, unplug the TR and determine if the short goes away. If the short is still present unplug the transmission harness and determine if the short goes away. If the short is still present, then the short is in the PCM or vehicle harness. Remove the suspect circuit(s) wire terminal from the PCM connector. If the short is still present, then the PCM has an internal failure, otherwise the failure is in the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4802 Transmission Position Switch/Sensor: Adjustments Transmission Range (TR) Sensor Adjustment Special Tool(s) Adjust 1. With the vehicle in NEUTRAL, position it on a hoist For additional information, refer to Maintenance/Service and Repair. 2. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the connector. 4. Disconnect the digital transmission range (TR) sensor electrical connector. 5. Remove the range selector lever cable end from the manual control lever. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4803 6. Remove the outer manual control lever. 7. Loosen but do not remove the digital TR sensor screws. 8. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. ^ Tighten to 8 Nm (71 inch lbs.) 9. Install the outer manual lever. ^ Tighten to 48 Nm (35 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4804 10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable end onto the manual control lever. 11. Reconnect the digital TR sensor electrical connector. 12. Move the rubber boot back over the connector. 13. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4805 14. Verify that the selector lever cable is adjusted correctly. 15. Verify that the vehicle will start in PARK and NEUTRAL and that the reverse lamps illuminate in REVERSE. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4806 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the connector. 4. Disconnect the digital transmission range (TR) sensor electrical connector. 5. Remove the selector lever cable from the manual control lever. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4807 6. Remove the outer manual control lever. 7. Remove the digital TR sensor. Installation 1. CAUTION: The digital transmission range sensor must fit flush against the boss on the case to prevent damage to the sensor. Install the digital TR sensor and 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 be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4808 ^ Tighten to 8 Nm (71 inch lbs.) 3. Install the outer manual lever. ^ Tighten to 48 Nm (35 ft. lbs.) 4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable to the manual control lever. 5. Connect the digital TR sensor electrical connector. 6. Move the rubber boot back over the connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4809 7. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. 8. Verify that the selector lever cable is adjusted correctly. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 4814 View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 4815 View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4818 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4819 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4820 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4821 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4822 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4823 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4824 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4825 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4826 Transmission Speed Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4827 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4828 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4829 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4830 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4831 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4832 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4833 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4834 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4835 Transmission Speed Sensor: Connector Views C193 C143 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4836 C164 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4839 6. Remove the selector lever cable and bracket. 7. Disconnect the turbine shaft speed (TSS) sensor electrical connector. 8. Remove the TSS sensor. 1 Remove the TSS sensor screw. 2 Remove the TSS sensor from the transmission. ^ Inspect the TSS sensor O-ring for damage. If damaged, install a new O-ring. Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the TSS sensor into the transmission. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4840 2 Tighten the TSS sensor screw. ^ Tighten to 14 Nm (10 ft. lbs.) 2. Connect the TSS sensor electrical connector. 3. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable and bracket. ^ Tighten to 40 Nm (30 ft. lbs.) 4. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4841 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Install the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 ft. lbs.) 7. Install the front driveshaft to the front differential. ^ Tighten to 18 Nm (13 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4842 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4843 6. Remove the selector lever cable and bracket. 7. Disconnect the heated oxygen sensor (HO2S) sensor connector from the transmission case. 8. Disconnect the output shaft speed (OSS) sensor electrical connector. 9. Remove the 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, install a new O-ring. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4844 Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the OSS sensor into the transmission. 2 Tighten the OSS sensor screw. ^ Tighten to 14 Nm (10 ft. lbs.) 2. Connect the OSS sensor electrical connector. 3. Connect the HO2S connector to the transmission case. 4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4845 cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable and bracket. ^ Tighten to 40 Nm (30 ft. lbs.) 5. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. 4WD vehicles 6. Install the front driveshaft in the vehicle. 7. Install the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4846 8. Install the front driveshaft to the front differential. ^ Tighten to 18 Nm (13 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4847 Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor Intermediate Shaft Speed Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4848 6. Remove the selector lever cable and bracket. 7. Disconnect the intermediate shaft speed sensor electrical connector. 8. Remove the intermediate shaft speed sensor. 1 Remove the intermediate shaft speed sensor screw. 2 Remove the intermediate shaft speed sensor from the transmission. ^ Inspect the intermediate shaft speed sensor O-ring for damage. If damaged, install a new O-ring. Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the intermediate shaft speed sensor into the transmission. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4849 2 Tighten the intermediate shaft speed sensor screw. ^ Tighten to 14 Nm (10 ft. lbs.) 2. Connect the intermediate shaft speed sensor electrical connector. 3. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable and bracket. ^ Tighten to 40 Nm (30 ft. lbs.) 4. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4850 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Install the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 ft. lbs.) 7. Install the front driveshaft to the front differential. ^ Tighten to 18 Nm (13 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4855 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4856 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4857 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4858 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4859 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4860 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4861 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4862 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4863 Transmission Temperature Sensor/Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4864 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4865 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4866 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4867 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4868 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4869 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4870 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 4871 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Brake Shift Interlock Actuator Removal 1. Remove the front floor console. For additional information, refer to Console. 2. Disconnect the brake shift lock actuator electrical connector. 3. Remove the screw and the brake shift lock actuator. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 4876 Installation 1. Install the brake shift lock actuator. 2. Connect the brake shift lock actuator electrical connector. 3. Install the front floor console. For additional information, refer to Console. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications Solenoid Operation Chart Solenoid Operation Chart Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4882 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4883 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4884 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4885 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4886 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4887 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4888 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4889 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4890 Shift Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4891 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4892 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4893 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4894 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4895 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4896 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4897 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4898 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 4899 Shift Solenoid: Testing and Inspection Pinpoint Tests - OSC Equipped Vehicle Special Tool(s) (Part 1) Special Tool(s) (Part 2) Shift Solenoid Pre-Diagnosis Any time an electrical connector or solenoid body is disconnected, inspect the connector for terminal condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install new as necessary. Use this shift solenoid operation information when carrying out Pinpoint Test A. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 4900 Solenoid Operation Chart (Part 1) Solenoid Operation Chart (Part 2) Shift Solenoid Failure Mode Chart Failed ON or OFF due to powertrain control module (PCM) and/or vehicle wiring concerns, solenoid electrically, mechanically or hydraulically stuck ON or OFF. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 4901 SSA, SSB SSC, SSD Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 4902 PC A, PC B, PC C (Part 1) PC A, PC B, PC C (Part 2) PC A, PC B, PC C (Part 3) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 4903 Shift Solenoid: Service and Repair Solenoid Body Assembly Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the drain plug and drain the fluid. 3. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. Disconnect the solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the gasket should be reused. Remove the 16 transmission fluid pan screws, fluid pan and gasket. 5. Remove the transmission fluid filter. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 4904 6. CAUTION: Do not damage the solenoid body connector pins. Remove the solenoid body bolts and remove the solenoid body by pulling down on the solenoid body and pushing down on the connector from the other side of the case. Installation 1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean automatic transmission fluid. 2. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur. Install the solenoid body. Tighten the bolts in sequence shown. ^ Tighten to 8 Nm (71 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 4905 3. CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be damaged. NOTE: Make sure that the fluid filter seals are correctly seated on the filter. Lubricate the seals and install the transmission fluid filter. ^ Tighten to 10 Nm (89 inch lbs.) 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage, if not damaged, the gasket should be reused. Install the transmission fluid pan and gasket and loosely install the screws. 5. Tighten the screws in a crisscross sequence. ^ Tighten to 11 Nm (8 ft. lbs.) 6. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the specification. NOTE: Always install new O-ring seals on vehicle harness connector. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission connector and connect the connector. ^ Tighten to 5 Nm (44 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 4906 7. Fill the transmission. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Recalls: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement Technical Service Bulletin # 09B11 Date: 100115 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on January 15, 2010. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Recalls: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 4915 FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website on January 15, 2010. Owner names and addresses will be available on January 31, 2010. 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 program 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 field service action. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected customers whose vehicles are not on your VIN list 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 service action. 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 service action 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 ^ Ford Motor Company will only refund owner-paid repairs covered by this program if the repair was performed before the date of the Owner Notification Letter. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ If a "stuck in park" event occurs, customers can override the brake shift interlock with information located in the Owner Guide. The 09B11 Owner Letter provides directions to locate the override information and includes a representative brake shift interlock owner guide attachment. There should be no emergency repair refunds after the customer mailings are complete. ^ Refunds will only be provided for the cost associated with the diagnosis and replacement of the transmission gearshift lever due to a "stuck in park" concern. ^ 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. ^ The refund period for repairs performed prior to the date of the Owner Notification Letter will expire on July 31, 2010. ^ Refund Claiming Information (submit on separate repair line). - Program Code: 09B11 - 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 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Recalls: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 4916 ^ 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 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. ^ Refer to ACESII manual for claims preparation and submission information. ^ PROGRAM TERMS: This program will be in effect until January 31, 2011 regardless of mileage. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this recall is 50415. DEALER PRICE For latest prices, 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 In some of the affected vehicles, the transmission gearshift lever may not move out of the park position even when the brake pedal is depressed. This "stuck in park" condition can develop due to silicon dioxide contamination building up on the contacts of the park detect switch located on the transmission gearshift lever. SERVICE PROCEDURE 1. Remove the front floor console. Refer to the appropriate WSM Section 501-12 Console - Front. 2. NOTICE: Electronic modules are sensitive to static electrical charges If the new circuit board is exposed to these charges, damage may result The circuit board should be handled by the plastic connector(s) and avoid touching any of the metal surfaces. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Recalls: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 4917 Disconnect the three electrical connectors from the white circuit board that is located on the lower RH section of the transmission gearshift lever See Figure 1. 3. Remove the circuit board case from the RH side of the transmission gearshift lever by releasing the two retainer clips See Figure 2. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Recalls: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 4918 4. Replace the circuit board See Figure 3. ^ Separate the upper circuit board case cover from the lower case containing the circuit board. ^ Remove and discard the circuit board Install the new circuit board. Snap the upper circuit board case cover and the lower case back together. 5. To reinstall the circuit board case, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Recalls: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 4919 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Recalls: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 4920 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Recalls: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 4921 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Customer Interest: > 07-12-9 > Jun > 07 > A/T - Manual Override Required to Shift From PARK Shifter A/T: Customer Interest A/T - Manual Override Required to Shift From PARK TSB 07-12-9 06/25/07 INTERMITTENT CONDITION - SHIFTER REQUIRES MANUAL OVERRIDE TO GET VEHICLE OUT OF PARK - VEHICLES BUILT ON OR BEFORE 11/14/2006 FORD: 2006-2007 Explorer 2007 Explorer Sport Trac, Explorer Sport Trac MERCURY: 2006-2007 Mountaineer, Mountaineer This article supersedes TSB 07-11-12 to update the production fix date. ISSUE Some 2006-2007 Explorer 4dr, Mountaineer and 2007 Explorer Sport Trac vehicles built on or before 11/14/2006 may exhibit an intermittent condition where the shifter may require the use of the manual override function to get the shifter out of park. This condition may be caused by chemicals migrating from the shifter lubricant, and being deposited on the shifter switch contacts. ACTION Follow the Service Procedure steps to correct the condition. NOTE THIS TSB SHOULD BE PERFORMED ON 2006 VEHICLES AND 2007 VEHICLES BUILT ON OR BEFORE 11/14/2006. THIS TSB DOES NOT APPLY TO VEHICLES BUILT AFTER 11/14/2006. SERVICE PROCEDURE 1. Check the electrical system and make sure the shifter is getting power from the BOO switch (actuate brake to confirm switch signal is getting to the shifter assembly). 2. Confirm the wiring in the shifter is okay (connections are made, no cut wires). 3. If there are no issues with wiring or other electrical components, follow Workshop Manual, Section 307-05, Removal and Installation of the Transmission Selector Lever and Selector Lever Cable Adjustment procedures to replace the Transmission Selector. Parts Block 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 071209A 2006-2007 1.0 Hr. Explorer/Mountaineer, 2007 Explorer Sport Trac 5R555/6R60 Transmission: Replace The Transmission Selector Lever Includes Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Customer Interest: > 07-12-9 > Jun > 07 > A/T - Manual Override Required to Shift From PARK > Page 4927 Time For Cable Adjustment (Do Not Use With 7210A) MT071209 Claim Additional Diagnosis Actual Or Labor Performed As Time Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 7210 49 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Customer Interest: > 07-3-8 > Feb > 07 > A/T - Manual Override Required To Get Out of 'PARK' Shifter A/T: Customer Interest A/T - Manual Override Required To Get Out of 'PARK' TSB 07-3-8 02/19/07 INTERMITTENT CONDITION - SHIFTER REQUIRES MANUAL OVERRIDE TO GET VEHICLE OUT OF PARK FORD: 2006-2007 Explorer 2007 Explorer Sport Trac, Explorer Sport Trac MERCURY: 2006-2007 Mountaineer, Mountaineer This article supersedes TSB 06-25-10 to update the vehicle model years. ISSUE Some 2006-2007 Explorer 4dr, Mountaineer and 2007 Explorer Sport Trac vehicles built on or before 1/23/2007 may exhibit an intermittent condition where the shifter may require the use of the manual override function to get the shifter out of park. This condition may be caused by chemicals migrating from the shifter lubricant, and being deposited on the shifter switch contacts. ACTION Follow the Service Procedure steps to correct the condition. NOTE THIS TSB SHOULD BE PERFORMED ON 2006 VEHICLES AND 2007 VEHICLES BUILT ON OR BEFORE 01/23/2007. THIS TSB DOES NOT APPLY TO VEHICLES BUILT AFTER 01/23/2007. SERVICE PROCEDURE 1. Check the electrical system and make sure the shifter is getting power from the BOO switch (actuate brake to confirm switch signal is getting to the shifter assembly). 2. Confirm the wiring in the shifter is ok (connections are made, no cut wires). 3. If there are no issues with wiring or other electrical components, follow Workshop Manual, Section 307-05, Removal and Installation of the Transmission Selector Lever and Selector Lever Cable Adjustment procedures to replace the Transmission Selector. Parts Block 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 070308A 2006-2007 1.0 Hr. Explorer/Mountaineer, 2007 Explorer Sport Trac 5R555/6R60 Transmission: Replace The Transmission Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > Customer Interest: > 07-3-8 > Feb > 07 > A/T - Manual Override Required To Get Out of 'PARK' > Page 4932 Selector Lever Includes Time For Cable Adjustment (Do Not Use With 7210A) DEALER CODING CONDITION BASIC PART NO. CODE 7210 49 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > 09B11 > Jan > 10 > Campaign A/T Shift Lever Circuit Board Replacement Technical Service Bulletin # 09B11 Date: 100115 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on January 15, 2010. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > 09B11 > Jan > 10 > Campaign A/T Shift Lever Circuit Board Replacement > Page 4938 FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website on January 15, 2010. Owner names and addresses will be available on January 31, 2010. 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 program 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 field service action. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected customers whose vehicles are not on your VIN list 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 service action. 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 service action 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 ^ Ford Motor Company will only refund owner-paid repairs covered by this program if the repair was performed before the date of the Owner Notification Letter. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ If a "stuck in park" event occurs, customers can override the brake shift interlock with information located in the Owner Guide. The 09B11 Owner Letter provides directions to locate the override information and includes a representative brake shift interlock owner guide attachment. There should be no emergency repair refunds after the customer mailings are complete. ^ Refunds will only be provided for the cost associated with the diagnosis and replacement of the transmission gearshift lever due to a "stuck in park" concern. ^ 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. ^ The refund period for repairs performed prior to the date of the Owner Notification Letter will expire on July 31, 2010. ^ Refund Claiming Information (submit on separate repair line). - Program Code: 09B11 - 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 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > 09B11 > Jan > 10 > Campaign A/T Shift Lever Circuit Board Replacement > Page 4939 ^ 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 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. ^ Refer to ACESII manual for claims preparation and submission information. ^ PROGRAM TERMS: This program will be in effect until January 31, 2011 regardless of mileage. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this recall is 50415. DEALER PRICE For latest prices, 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 In some of the affected vehicles, the transmission gearshift lever may not move out of the park position even when the brake pedal is depressed. This "stuck in park" condition can develop due to silicon dioxide contamination building up on the contacts of the park detect switch located on the transmission gearshift lever. SERVICE PROCEDURE 1. Remove the front floor console. Refer to the appropriate WSM Section 501-12 Console - Front. 2. NOTICE: Electronic modules are sensitive to static electrical charges If the new circuit board is exposed to these charges, damage may result The circuit board should be handled by the plastic connector(s) and avoid touching any of the metal surfaces. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > 09B11 > Jan > 10 > Campaign A/T Shift Lever Circuit Board Replacement > Page 4940 Disconnect the three electrical connectors from the white circuit board that is located on the lower RH section of the transmission gearshift lever See Figure 1. 3. Remove the circuit board case from the RH side of the transmission gearshift lever by releasing the two retainer clips See Figure 2. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > 09B11 > Jan > 10 > Campaign A/T Shift Lever Circuit Board Replacement > Page 4941 4. Replace the circuit board See Figure 3. ^ Separate the upper circuit board case cover from the lower case containing the circuit board. ^ Remove and discard the circuit board Install the new circuit board. Snap the upper circuit board case cover and the lower case back together. 5. To reinstall the circuit board case, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > 09B11 > Jan > 10 > Campaign A/T Shift Lever Circuit Board Replacement > Page 4942 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > 09B11 > Jan > 10 > Campaign A/T Shift Lever Circuit Board Replacement > Page 4943 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > 09B11 > Jan > 10 > Campaign A/T Shift Lever Circuit Board Replacement > Page 4944 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > 07-12-9 > Jun > 07 > A/T Manual Override Required to Shift From PARK Shifter A/T: All Technical Service Bulletins A/T - Manual Override Required to Shift From PARK TSB 07-12-9 06/25/07 INTERMITTENT CONDITION - SHIFTER REQUIRES MANUAL OVERRIDE TO GET VEHICLE OUT OF PARK - VEHICLES BUILT ON OR BEFORE 11/14/2006 FORD: 2006-2007 Explorer 2007 Explorer Sport Trac, Explorer Sport Trac MERCURY: 2006-2007 Mountaineer, Mountaineer This article supersedes TSB 07-11-12 to update the production fix date. ISSUE Some 2006-2007 Explorer 4dr, Mountaineer and 2007 Explorer Sport Trac vehicles built on or before 11/14/2006 may exhibit an intermittent condition where the shifter may require the use of the manual override function to get the shifter out of park. This condition may be caused by chemicals migrating from the shifter lubricant, and being deposited on the shifter switch contacts. ACTION Follow the Service Procedure steps to correct the condition. NOTE THIS TSB SHOULD BE PERFORMED ON 2006 VEHICLES AND 2007 VEHICLES BUILT ON OR BEFORE 11/14/2006. THIS TSB DOES NOT APPLY TO VEHICLES BUILT AFTER 11/14/2006. SERVICE PROCEDURE 1. Check the electrical system and make sure the shifter is getting power from the BOO switch (actuate brake to confirm switch signal is getting to the shifter assembly). 2. Confirm the wiring in the shifter is okay (connections are made, no cut wires). 3. If there are no issues with wiring or other electrical components, follow Workshop Manual, Section 307-05, Removal and Installation of the Transmission Selector Lever and Selector Lever Cable Adjustment procedures to replace the Transmission Selector. Parts Block 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 071209A 2006-2007 1.0 Hr. Explorer/Mountaineer, 2007 Explorer Sport Trac 5R555/6R60 Transmission: Replace The Transmission Selector Lever Includes Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > 07-12-9 > Jun > 07 > A/T Manual Override Required to Shift From PARK > Page 4949 Time For Cable Adjustment (Do Not Use With 7210A) MT071209 Claim Additional Diagnosis Actual Or Labor Performed As Time Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 7210 49 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > 07-3-8 > Feb > 07 > A/T Manual Override Required To Get Out of 'PARK' Shifter A/T: All Technical Service Bulletins A/T - Manual Override Required To Get Out of 'PARK' TSB 07-3-8 02/19/07 INTERMITTENT CONDITION - SHIFTER REQUIRES MANUAL OVERRIDE TO GET VEHICLE OUT OF PARK FORD: 2006-2007 Explorer 2007 Explorer Sport Trac, Explorer Sport Trac MERCURY: 2006-2007 Mountaineer, Mountaineer This article supersedes TSB 06-25-10 to update the vehicle model years. ISSUE Some 2006-2007 Explorer 4dr, Mountaineer and 2007 Explorer Sport Trac vehicles built on or before 1/23/2007 may exhibit an intermittent condition where the shifter may require the use of the manual override function to get the shifter out of park. This condition may be caused by chemicals migrating from the shifter lubricant, and being deposited on the shifter switch contacts. ACTION Follow the Service Procedure steps to correct the condition. NOTE THIS TSB SHOULD BE PERFORMED ON 2006 VEHICLES AND 2007 VEHICLES BUILT ON OR BEFORE 01/23/2007. THIS TSB DOES NOT APPLY TO VEHICLES BUILT AFTER 01/23/2007. SERVICE PROCEDURE 1. Check the electrical system and make sure the shifter is getting power from the BOO switch (actuate brake to confirm switch signal is getting to the shifter assembly). 2. Confirm the wiring in the shifter is ok (connections are made, no cut wires). 3. If there are no issues with wiring or other electrical components, follow Workshop Manual, Section 307-05, Removal and Installation of the Transmission Selector Lever and Selector Lever Cable Adjustment procedures to replace the Transmission Selector. Parts Block 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 070308A 2006-2007 1.0 Hr. Explorer/Mountaineer, 2007 Explorer Sport Trac 5R555/6R60 Transmission: Replace The Transmission Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > 07-3-8 > Feb > 07 > A/T Manual Override Required To Get Out of 'PARK' > Page 4954 Selector Lever Includes Time For Cable Adjustment (Do Not Use With 7210A) DEALER CODING CONDITION BASIC PART NO. CODE 7210 49 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 07-12-9 > Jun > 07 > A/T - Manual Override Required to Shift From PARK Shifter A/T: All Technical Service Bulletins A/T - Manual Override Required to Shift From PARK TSB 07-12-9 06/25/07 INTERMITTENT CONDITION - SHIFTER REQUIRES MANUAL OVERRIDE TO GET VEHICLE OUT OF PARK - VEHICLES BUILT ON OR BEFORE 11/14/2006 FORD: 2006-2007 Explorer 2007 Explorer Sport Trac, Explorer Sport Trac MERCURY: 2006-2007 Mountaineer, Mountaineer This article supersedes TSB 07-11-12 to update the production fix date. ISSUE Some 2006-2007 Explorer 4dr, Mountaineer and 2007 Explorer Sport Trac vehicles built on or before 11/14/2006 may exhibit an intermittent condition where the shifter may require the use of the manual override function to get the shifter out of park. This condition may be caused by chemicals migrating from the shifter lubricant, and being deposited on the shifter switch contacts. ACTION Follow the Service Procedure steps to correct the condition. NOTE THIS TSB SHOULD BE PERFORMED ON 2006 VEHICLES AND 2007 VEHICLES BUILT ON OR BEFORE 11/14/2006. THIS TSB DOES NOT APPLY TO VEHICLES BUILT AFTER 11/14/2006. SERVICE PROCEDURE 1. Check the electrical system and make sure the shifter is getting power from the BOO switch (actuate brake to confirm switch signal is getting to the shifter assembly). 2. Confirm the wiring in the shifter is okay (connections are made, no cut wires). 3. If there are no issues with wiring or other electrical components, follow Workshop Manual, Section 307-05, Removal and Installation of the Transmission Selector Lever and Selector Lever Cable Adjustment procedures to replace the Transmission Selector. Parts Block 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 071209A 2006-2007 1.0 Hr. Explorer/Mountaineer, 2007 Explorer Sport Trac 5R555/6R60 Transmission: Replace The Transmission Selector Lever Includes Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 07-12-9 > Jun > 07 > A/T - Manual Override Required to Shift From PARK > Page 4960 Time For Cable Adjustment (Do Not Use With 7210A) MT071209 Claim Additional Diagnosis Actual Or Labor Performed As Time Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 7210 49 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 07-3-8 > Feb > 07 > A/T - Manual Override Required To Get Out of 'PARK' Shifter A/T: All Technical Service Bulletins A/T - Manual Override Required To Get Out of 'PARK' TSB 07-3-8 02/19/07 INTERMITTENT CONDITION - SHIFTER REQUIRES MANUAL OVERRIDE TO GET VEHICLE OUT OF PARK FORD: 2006-2007 Explorer 2007 Explorer Sport Trac, Explorer Sport Trac MERCURY: 2006-2007 Mountaineer, Mountaineer This article supersedes TSB 06-25-10 to update the vehicle model years. ISSUE Some 2006-2007 Explorer 4dr, Mountaineer and 2007 Explorer Sport Trac vehicles built on or before 1/23/2007 may exhibit an intermittent condition where the shifter may require the use of the manual override function to get the shifter out of park. This condition may be caused by chemicals migrating from the shifter lubricant, and being deposited on the shifter switch contacts. ACTION Follow the Service Procedure steps to correct the condition. NOTE THIS TSB SHOULD BE PERFORMED ON 2006 VEHICLES AND 2007 VEHICLES BUILT ON OR BEFORE 01/23/2007. THIS TSB DOES NOT APPLY TO VEHICLES BUILT AFTER 01/23/2007. SERVICE PROCEDURE 1. Check the electrical system and make sure the shifter is getting power from the BOO switch (actuate brake to confirm switch signal is getting to the shifter assembly). 2. Confirm the wiring in the shifter is ok (connections are made, no cut wires). 3. If there are no issues with wiring or other electrical components, follow Workshop Manual, Section 307-05, Removal and Installation of the Transmission Selector Lever and Selector Lever Cable Adjustment procedures to replace the Transmission Selector. Parts Block 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 070308A 2006-2007 1.0 Hr. Explorer/Mountaineer, 2007 Explorer Sport Trac 5R555/6R60 Transmission: Replace The Transmission Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 07-3-8 > Feb > 07 > A/T - Manual Override Required To Get Out of 'PARK' > Page 4965 Selector Lever Includes Time For Cable Adjustment (Do Not Use With 7210A) DEALER CODING CONDITION BASIC PART NO. CODE 7210 49 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement Technical Service Bulletin # 09B11 Date: 100115 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on January 15, 2010. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 4971 FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website on January 15, 2010. Owner names and addresses will be available on January 31, 2010. 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 program 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 field service action. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected customers whose vehicles are not on your VIN list 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 service action. 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 service action 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 ^ Ford Motor Company will only refund owner-paid repairs covered by this program if the repair was performed before the date of the Owner Notification Letter. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ If a "stuck in park" event occurs, customers can override the brake shift interlock with information located in the Owner Guide. The 09B11 Owner Letter provides directions to locate the override information and includes a representative brake shift interlock owner guide attachment. There should be no emergency repair refunds after the customer mailings are complete. ^ Refunds will only be provided for the cost associated with the diagnosis and replacement of the transmission gearshift lever due to a "stuck in park" concern. ^ 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. ^ The refund period for repairs performed prior to the date of the Owner Notification Letter will expire on July 31, 2010. ^ Refund Claiming Information (submit on separate repair line). - Program Code: 09B11 - 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 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 4972 ^ 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 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. ^ Refer to ACESII manual for claims preparation and submission information. ^ PROGRAM TERMS: This program will be in effect until January 31, 2011 regardless of mileage. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this recall is 50415. DEALER PRICE For latest prices, 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 In some of the affected vehicles, the transmission gearshift lever may not move out of the park position even when the brake pedal is depressed. This "stuck in park" condition can develop due to silicon dioxide contamination building up on the contacts of the park detect switch located on the transmission gearshift lever. SERVICE PROCEDURE 1. Remove the front floor console. Refer to the appropriate WSM Section 501-12 Console - Front. 2. NOTICE: Electronic modules are sensitive to static electrical charges If the new circuit board is exposed to these charges, damage may result The circuit board should be handled by the plastic connector(s) and avoid touching any of the metal surfaces. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 4973 Disconnect the three electrical connectors from the white circuit board that is located on the lower RH section of the transmission gearshift lever See Figure 1. 3. Remove the circuit board case from the RH side of the transmission gearshift lever by releasing the two retainer clips See Figure 2. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 4974 4. Replace the circuit board See Figure 3. ^ Separate the upper circuit board case cover from the lower case containing the circuit board. ^ Remove and discard the circuit board Install the new circuit board. Snap the upper circuit board case cover and the lower case back together. 5. To reinstall the circuit board case, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 4975 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 4976 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 4977 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever Shifter A/T: Service and Repair Selector Lever Selector Lever Selector Lever Removal 1. Remove the front floor console. For additional information, refer to Console. 2. Disconnect the selector lever cable from the selector lever. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever > Page 4980 3. Disconnect the selector lever cable from the selector lever housing. 4. Disconnect the electrical connector. 5. Disconnect the wiring harness from the selector lever housing. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever > Page 4981 6. Remove the 4 nuts and remove the selector lever housing from the vehicle. Installation NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. 1. Install the selector lever housing. ^ Tighten to 9 Nm (80 inch lbs.) 2. Connect the wiring harness to the selector lever housing. 3. Connect the electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever > Page 4982 4. Install the selector lever cable onto the selector lever housing. 5. Connect the selector lever cable onto the selector lever. 6. Install the front floor console. For additional information, refer to Console. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever > Page 4983 Shifter A/T: Service and Repair Selector Lever Knob Selector Lever Knob Selector Lever Knob Removal 1. Remove the front floor console. For additional information, refer to Console. 2. Disconnect the transmission control (TC) switch electrical connector and feed the wire through the selector lever housing. 3. Slide the selector lever lower trim cover downward. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever > Page 4984 4. Remove the set screw and remove the selector lever knob while routing the TC switch harness out of the selector lever housing. Installation 1. CAUTION: Do not overtighten the set screw or damage to the selector lever knob may occur. Install the selector lever knob and set screw while routing the TC switch harness through the selector lever housing. ^ Tighten to 3 Nm (27 inch lbs.) 2. Slide the selector lever lower trim cover upward. 3. Feed the wire through the selector lever housing and connect the TC switch electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever > Page 4985 4. Install the front floor console. For additional information, refer to Console. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever > Page 4986 Shifter A/T: Service and Repair Selector Lever Bezel Selector Lever Bezel Removal 1. Remove the front floor console. For additional information, refer to Console. 2. Disconnect the transmission control (TC) switch electrical connector and feed the wire through the selector lever housing. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever > Page 4987 3. Slide the selector lever lower trim cover downward. 4. Remove the set screw and remove the selector lever knob while routing the TC switch harness out of the selector lever housing. 5. Remove the bezel from the selector lever housing. Installation 1. Install the bezel onto the selector lever housing. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever > Page 4988 2. CAUTION: Do not overtighten the set screw or damage to the selector lever knob may occur. Install the selector lever knob and set screw while routing the TC switch harness through the selector lever housing. ^ Tighten to 3 Nm (27 inch lbs.) 3. Slide the selector lever lower trim cover upward. 4. Feed the wire through the selector lever housing and connect the TC switch electrical connector. 5. Install the front floor console. For additional information, refer to Console. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments Shift Cable: Adjustments Selector Lever Cable Adjustment - 5R55S 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Place the selector lever in the PARK position. 3. Move the selector lever 3 detents. This should be the (D) position. 4. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 5. Disconnect the selector lever cable end from the manual lever. 6. Rotate the manual lever clockwise until the travel stops. Then rotate the manual lever counterclockwise 3 detents. This should be the (D) position. 7. With the selector lever cable end disconnected, unlock the tab on the selector lever cable end by sliding it up. 8. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4993 snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Carry out these adjustments on the selector lever cable end: 1 Make sure that the selector lever cable end slides forward and backward. 2 Connect the selector lever cable end onto the manual control lever. 3 Lock the selector lever cable end into place by pressing the lock tab down. 9. NOTE: If the shield is loose on the cable, install a new shield. Install and secure the cable shield. 10. Verify that the engine will start in PARK and NEUTRAL. Verify that the reverse lamps will illuminate in the REVERSE position. If not, check the adjustment of the transmission range (TR) sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4994 Shift Cable: Service and Repair Selector Lever Cable Vehicles Equipped with a 6R60 Transmission Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4995 Vehicles Equipped with a 5R55S Transmission Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the center console left side panel. 3. With the selector lever in PARK, disconnect the selector lever cable from the selector lever. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4996 4. Disconnect the selector lever cable from the selector lever housing. 5. Pull the cable and grommet through the floorpan. Vehicles equipped with a 6R60 transmission 6. Remove the cable shield by prying on the shield closest to the boot, then sliding the shield away from the boot. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4997 7. Unlock the lock tab and disconnect the selector lever cable end from the transmission manual lever. 8. Disconnect the selector lever cable from the bracket and remove the cable. Vehicles equipped with a 5R55S transmission 9. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 10. Unlock the lock tab and disconnect the selector lever cable end from the transmission manual lever. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4998 11. Disconnect the selector lever cable from the bracket and remove the cable. Installation Vehicles equipped with a 6R60 transmission NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. 1. Install the selector lever cable into the bracket. 2. Connect the selector lever cable end onto the transmission manual lever and lock the lock tab. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4999 3. NOTE: If the shield is loose, install a new shield. Install the cable shield. Vehicles equipped with a 5R55S transmission NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. 4. Install the selector lever cable into the bracket. 5. Connect the selector lever cable end onto the transmission manual lever. 6. NOTE: If the shield is loose, install a new shield. Install the cable shield. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 5000 All vehicles 7. Push the cable and grommet through the floorpan. 8. Connect the selector lever cable onto the selector lever housing. 9. Connect the selector lever cable onto the selector lever. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 5001 10. Install the center console left side panel. 11. Verify the engine will start in PARK and NEUTRAL and the reversing lamps illuminate in REVERSE. If not, readjust the selector lever cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor/Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5006 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5007 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5008 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5009 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5010 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5011 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5012 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5013 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5014 Throttle Position Sensor/Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5015 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5016 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5017 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5018 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5019 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5020 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5021 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5022 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications Torque Converter: Specifications Stall Speed Chart Stall Speed Chart Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > Page 5026 Torque Converter: Description and Operation Torque Converter The torque converter transmits and multiplies torque. The torque converter is a 4-element device: ^ Impeller assembly ^ Turbine and damper assembly ^ Reactor assembly ^ Clutch The standard torque converter components operate as follows: ^ Rotation of the converter housing and impeller set the fluid in motion. ^ The turbine reacts to the fluid motion from the impeller, transferring rotation to the geartrain through the input shaft. ^ The reactor redirects fluid going back into the impeller, allowing for torque multiplication. ^ The clutch and damper assembly dampens powertrain torsional vibration and provides a direct mechanical connection for improved efficiency. ^ Power is transmitted from the torque converter to the planetary gearsets and other components through the input shaft. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Torque Converter Diagnosis Torque Converter: Testing and Inspection Torque Converter Diagnosis Torque Converter Diagnosis Prior to installing a new torque converter, all diagnostic procedures must be followed. This is to prevent the unnecessary installation of good torque converters. Only after a complete diagnostic evaluation can the decision be made to install a new or remanufactured torque converter. Begin with the normal diagnostic procedures as follows: 1. Preliminary Inspection. 2. Know and Understand the Customer Concern. 3. Verify the Concern - Carry out the Torque Converter Clutch Operation Test. See: Torque Converter Operation Test 4. Carry out Diagnostic Procedures. ^ Run on-board diagnostics. Refer to On-Board Diagnostics with scan tool. See: Transmission Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies/Diagnostics Repair all non-transmission related DTCs first. - Repair all transmission DTCs. - Rerun on-board diagnostic to verify repair. ^ Carry out the Line Pressure Test. ^ Carry out the Stall Speed Test. See: Transmission Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Special Testing Procedures/Stall Speed Test ^ Carry out the Diagnosis by Symptom Index. See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Diagnosis By Symptom Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed, diagnose and service as necessary before servicing the torque converter. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Torque Converter Diagnosis > Page 5029 Torque Converter: Testing and Inspection Torque Converter Operation Test Torque Converter Operation Test This test verifies that the torque converter clutch control system and the torque converter are operating correctly. 1. Carry out the Quick Test. Refer to On-Board Diagnostics with Scan Tool. Check for DTCs. Refer to the Diagnostic Trouble Code (DTC) Charts. See: Transmission Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions 2. Connect a tachometer to the engine. 3. Bring the engine to normal operating temperature by driving the vehicle at highway speeds for approximately 15 minutes in (D) position. 4. After normal operating temperature is reached, maintain a constant vehicle speed of about 80 km/h (50 mph) and tap brake pedal with the left foot. 5. The engine rpm should increase when the brake pedal is tapped and decrease about 5 seconds after the pedal is released. If this does not occur, refer to Torque Converter Operation Concerns in Diagnosis By Symptom. See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Diagnosis By Symptom 6. If the vehicle stalls in (D) or MANUAL 2 at idle with vehicle at a stop, move the transmission range selector lever to MANUAL 1 position. If the vehicle stalls, refer to Diagnosis By Symptom, Torque Converter Operation Concerns. Repair as necessary. If the vehicle does not stall in (D), refer to Diagnosis By Symptom. See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Diagnosis By Symptom Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Torque Converter Diagnosis > Page 5030 Torque Converter: Testing and Inspection Torque Converter Torque Converter 1. A new or remanufactured torque converter must be installed if one or more of these statements is true: ^ A torque converter malfunction has been determined based on complete diagnostic procedures. ^ Converter stud or studs, impeller hub or bushing are damaged. ^ Discoloration (due to overheating). ^ Evidence of transmission assembly or fluid contamination due to these transmission or converter failure modes: Major metallic failure. - Multiple clutches or clutch plate failures. - Sufficient component wear which results in metallic contamination. - Internal torque converter contamination present. For additional information, refer to Torque Converter Contamination Inspection. See: Testing and Inspection/Component Tests and General Diagnostics/Torque Converter Contamination Inspection Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Torque Converter Diagnosis > Page 5031 Torque Converter: Testing and Inspection Torque Converter Contamination Inspection Torque Converter Contamination Inspection CAUTION: Do not use water-based cleaners, mineral spirits, brake cleaner or solvents that may contain acetone, xylene or heptane to clean and/or flush the transmission assembly, transmission components and the torque converter or transmission damage will occur. Use only clean transmission fluid designated for the transmission/converter being serviced. CAUTION: The torque converter drain plug and seal are not reusable. If equipped, discard the drain plug and seal, then install a new drain plug assembly. 1. If a new or remanufactured torque converter is not being installed, these steps must be completed. 2. With the torque converter on a bench, pour a small amount of transmission fluid from the torque converter onto an absorbent white tissue or through a paper filter and examine the fluid. 3. Observe the color and odor of the fluid. The fluid should be red, not brown or black. Odor may indicate an overheating condition such as clutch disc or band failure. 4. Examine the stain on the tissue for evidence of particles (spec of any kind). Examine the fluid level indicator for signs of antifreeze (gum or varnish). If particles are present in the fluid or there is evidence of engine coolant or water, a new torque converter must be installed. 5. If there are no particles or contamination present, drain the remainder of the transmission fluid from the torque converter. 6. Add 1.9L (2 qt) of clean automatic transmission fluid into the converter and agitate by hand. 7. Thoroughly drain the fluid. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications Solenoid Operation Chart Solenoid Operation Chart Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5037 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5038 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5039 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5040 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5041 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5042 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5043 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5044 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5045 Torque Converter Clutch Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5046 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5047 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5048 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5049 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5050 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5051 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5052 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5053 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5054 Torque Converter Clutch Solenoid: Service and Repair Solenoid Body Assembly Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the drain plug and drain the fluid. 3. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. Disconnect the solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the gasket should be reused. Remove the 16 transmission fluid pan screws, fluid pan and gasket. 5. Remove the transmission fluid filter. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5055 6. CAUTION: Do not damage the solenoid body connector pins. Remove the solenoid body bolts and remove the solenoid body by pulling down on the solenoid body and pushing down on the connector from the other side of the case. Installation 1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean automatic transmission fluid. 2. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur. Install the solenoid body. Tighten the bolts in sequence shown. ^ Tighten to 8 Nm (71 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5056 3. CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be damaged. NOTE: Make sure that the fluid filter seals are correctly seated on the filter. Lubricate the seals and install the transmission fluid filter. ^ Tighten to 10 Nm (89 inch lbs.) 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage, if not damaged, the gasket should be reused. Install the transmission fluid pan and gasket and loosely install the screws. 5. Tighten the screws in a crisscross sequence. ^ Tighten to 11 Nm (8 ft. lbs.) 6. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the specification. NOTE: Always install new O-ring seals on vehicle harness connector. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission connector and connect the connector. ^ Tighten to 5 Nm (44 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5057 7. Fill the transmission. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Mechanical Specifications Transmission Cooler: Mechanical Specifications Torque Specifications Torque Specifications Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Mechanical Specifications > Page 5062 Transmission Cooler: Capacity Specifications General Specifications General Specifications General Specifications Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Mechanical Specifications > Page 5063 Transmission Cooler: Fluid Type Specifications General Specifications General Specifications General Specifications Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Transmission Cooler: Initial Inspection and Diagnostic Overview Transmission Cooling CAUTION: Whenever a transmission has been disassembled to install new parts, a new transmission fluid cooler must be installed and the transmission fluid cooler tubes must be cleaned and backflushed. NOTE: Cleaning and backflushing the transmission fluid cooling system (along with normal cleaning and inspection procedures, as outlined during disassembly and assembly) will keep contamination from reentering the transmission and causing a repeat repair. When internal wear or damage has occurred in the transmission, metal particles, clutch plate material or band material may have been carried into the torque converter and transmission fluid cooler. These contaminants are a major cause of recurring transmission troubles and must be removed from the system before the transmission is put back in use. Inspection and Verification When fluid leakage is found in the fluid cooler, install a new fluid cooler. When there is evidence of transmission assembly or fluid contamination due to these transmission failure modes, install a new fluid cooler. ^ Major metallic failure ^ Multiple clutches or clutch plate failure ^ Sufficient component wear which results in metallic contamination Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5066 Transmission Cooler: Symptom Related Diagnostic Procedures Symptom Chart Symptom Chart Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5067 Transmission Cooler: Component Tests and General Diagnostics Transmission Fluid Cooler Special Tool(s) Material Transmission Fluid Cooler Flow Test CAUTION: Whenever a transmission has been disassembled to install new parts or a new or remanufactured transmission has been installed, a new transmission fluid cooler (either in-tank, auxiliary or OTA) if equipped, will need to be installed. Using a suitable torque converter/fluid cooler cleaner, clean and backflush the transmission fluid cooler tubes. CAUTION: Use only clean automatic transmission fluid specified for this transmission. Do not use supplemental fluid additives, treatments or cleaning agents. The use of these materials may affect transmission operation and result in internal damage to the transmission. CAUTION: When internal wear or damage has occurred in the transmission, metal particles, clutch plate material or band material may have been carried into the transmission fluid cooler. These contaminants are a major cause of recurring transmission concerns and must be removed from the system before the transmission is put back into use. When evidence of transmission fluid contamination (such as metal particles, clutch plate material or band material) is found in the cooling system, the transmission fluid cooler flow test should be carried out. If the transmission cooling system fails the transmission fluid cooler flow test, install a new transmission fluid cooler and flush out the fluid cooler lines. If installing a new transmission fluid cooler, use only factory approved components. CAUTION: The transmission fluid must be at normal operating temperature 85°C - 93°C (185°F 200°F) to make sure that the cooler bypass is open. The cooler bypass is located in the main control valve body. The transmission fluid at normal operating temperature will be hot. NOTE: The engine idle, transmission linkage/cable adjustment, fluid level and line pressure must be within specification before carrying out this test. For information on engine idle diagnosis, refer to Computers and Control Systems. For information on fluid level check, refer to Transmission Fluid Level Check. See: Fluid - A/T/Service and Repair/Transmission Fluid Level Check 1. Place the transmission range selector lever into PARK. 2. Raise the vehicle on a hoist and place suitable safety stands under the vehicle. Refer to Maintenance/Service and Repair. 3. Hold the large drain plug with a wrench, and remove the small (center) fluid level indicating plug using a 3/16-inch Allen key. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5068 4. Install the special tool into the pan. 5. Remove the cooler return line (upper line) from the fitting on the transmission case. 6. Connect one end of a clear hose to the cooler return line and route the other end of the hose to the special tool in the pan. 7. Remove the safety stands and lower the vehicle. 8. Start the engine and run at idle. 9. With the engine running, raise the vehicle on a hoist and place suitable safety stands under the vehicle. Refer to Maintenance/Service and Repair. 10. Monitor the transmission fluid temperature to make sure that the transmission fluid is at normal operating temperature 85°C - 93°C (185°F - 200° F). 11. Once a steady flow of fluid (without air bubbles) is observed, remove the hose from the special tool and place the hose in a measuring container for 15 seconds. After 15 seconds, place the hose back onto the special tool. Lower the vehicle and turn the engine OFF. Measure the amount of fluid in the container. If adequate flow was observed, approximately 208 ml (7 oz) will be in the measuring container. The test is complete. Reconnect the cooler line and install the fluid fill plug. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5069 12. If the flow is not liberal, disconnect the hose from the cooler return line and connect the hose to the cooler inlet (lower fitting) on the transmission case. Reconnect the cooler return line to the case (upper fitting). ^ Tighten to 40 Nm (30 ft. lbs.) 13. Repeat Steps 8 through 11. If flow is now approximately 208 ml (7 oz) in 15 seconds, the cooler lines and auxiliary cooler must be cleaned. Carry out this entire test after the backflushing and cleaning procedure. If, after carrying out the backflushing and cleaning procedure, the flow is still not adequate, new cooler lines and/or an auxiliary cooler must be installed. If the flow from the case is still not adequate after the installation of new cooler lines and/or an auxiliary cooler (208 ml [7 oz] in 15 seconds), the pump and/or torque converter may be at fault. Carry out the appropriate procedures for diagnosis and repair. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures Transmission Cooler: Procedures Transmission Fluid Cooler - Backflushing and Cleaning Material CAUTION: Whenever a transmission has been disassembled to install new parts or a new or remanufactured transmission has been installed, a new transmission fluid cooler, either in-tank, auxiliary or oil to air (OTA), if equipped will need to be installed. Using a suitable torque converter/fluid cooler cleaner, clean and backflush the transmission fluid cooler tubes. CAUTION: Do not use water-based cleaners, mineral spirits, brake cleaner or solvents that may contain acetone, xylene or heptane to clean and/or flush the transmission assembly, transmission components and the torque converter or transmission damage will occur. Use only clean transmission fluid designated for the transmission/converter being serviced. When internal wear or damage has occurred in the transmission, metal particles, clutch plate material or band material may have been carried into the transmission fluid cooler. These contaminants are a major cause of recurring transmission concerns and must be removed from the system before the transmission is put back in use. 1. Conduct backflushing with a suitable torque converter/transmission fluid cooler cleaner. Test the equipment to make sure that a vigorous fluid flow is present before proceeding. Install a new system filter if flow is weak or contaminated. 2. Remove and discard the in-line transmission fluid filter, if equipped. 3. To aid in attaching the cleaner to the transmission steel cooler lines, connect 2 additional rubber hoses to the transmission end of the steel transmission cooler lines as described. ^ Connect the cleaner tank pressure line to the steel transmission cooler return line (longest line). ^ Connect a tank return hose to the steel transmission cooler pressure line (shorter line). Place the outlet end of this hose in the solvent tank reservoir. 4. Turn on the pump and allow the transmission fluid to circulate a minimum of 5 minutes (cycling switch on and off will help dislodge contaminants in the cooler system). 5. Switch off the pump and disconnect the pressure hose from the transmission cooler return line. 6. Use compressed air to blow out the cooler(s) and lines (blow air into the transmission cooler return line) until all the fluid is removed. 7. Remove the rubber return hose from the remaining steel cooler line. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures > Page 5072 Transmission Cooler: Removal and Replacement Auxiliary Transmission Fluid Cooler Material Removal Mountaineer 1. Remove the grille fasteners and the grille. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures > Page 5073 Explorer 2. Remove the bumper cover. All vehicles 3. Remove the inner grille air deflector. 4. Push the lower air deflector down past the transmission fluid cooler. 5. Disconnect the transmission fluid cooler hoses. ^ Remove and discard the transmission fluid cooler hoses and the clamps. 6. Remove the upper transmission fluid cooler bolt. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures > Page 5074 7. Remove the lower transmission fluid cooler bolts and the transmission fluid cooler. Installation All vehicles 1. Install the transmission fluid cooler and the lower transmission fluid cooler bolts. ^ Tighten to 7 Nm (62 inch lbs.) 2. Install the upper transmission fluid cooler bolt. ^ Tighten to 7 Nm (62 inch lbs.) 3. NOTE: Clean the cooler tube stems with degreaser prior to installing the hoses. Using new hoses and clamps, install the transmission fluid cooler hoses. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures > Page 5075 4. Push the lower air deflector back into place. 5. Install the inner grille air deflector. Mountaineer 6. Install the grille and the fasteners. Explorer 7. Install the bumper cover. All vehicles 8. Fill and check the transmission fluid. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 (TCIL) The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Mode Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5083 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5084 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5085 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5086 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5087 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5088 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5089 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5090 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5091 Transmission Mode Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5092 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5093 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5094 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5095 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5096 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5097 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5098 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5099 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Description and Operation > Transmission Control (TC) Switch Transmission Mode Switch: Description and Operation Transmission Control (TC) Switch Transmission Control (TC) Switch The transmission control (TC) switch is a momentary contact switch located on the selector lever knob. Pushing the TC switch will either disengage or engage the overdrive function of the transmission. If OVERDRIVE is disengaged, the message O/D OFF will illuminate on the instrument panel. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Description and Operation > Transmission Control (TC) Switch > Page 5102 Transmission Mode Switch: Description and Operation Transmission Control Switch (TCS) TRANSMISSION CONTROL SWITCH (TCS) Typical Transmission Control Switch (TCS) Typical Transmission Control Switch (TCS) The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature, the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage overdrive. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Description and Operation > Page 5103 Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch Removal 1. Remove the transmission selector lever knob. 2. Remove the transmission control switch from the knob. Installation 1. Install the transmission control switch into the knob. 2. Install the transmission selector lever knob. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair Transmission Mount: Service and Repair Transmission Support Insulator - Rear Wheel Drive (RWD) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Support the transmission with a transmission jack. 3. Remove the transmission support insulator nuts. 4. Remove the 2 transmission support insulator bolts. 5. Raise the transmission and remove the transmission support insulator. Installation 1. Install the transmission support insulator and lower the transmission onto the transmission support insulator. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Page 5107 2. Install the transmission support insulator bolts. ^ Tighten to 90 Nm (66 ft. lbs.) 3. Install the transmission support insulator nuts. ^ Tighten to 90 Nm (66 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5113 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5114 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5115 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5116 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5117 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5118 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5119 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5120 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5121 Transmission Position Switch/Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5122 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5123 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5124 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5125 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5126 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5127 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5128 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5129 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5130 C167 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5131 Transmission Position Switch/Sensor: Testing and Inspection Digital Transmission Range (TR) Sensor Diagnosis Chart Digital Transmission Range (TR) Sensor Diagnosis Chart Wiggle Test Information for Open/Shorts ^ TR4, TR3A, TR2 and TR1 are all closed in PARK. PARK is a good position to check for intermittent open circuits (with scan tool monitoring TRD). ^ TR4, TR3A, TR2 and TR1 are all open in OVERDRIVE, so OVERDRIVE is a good position to check for shorts to ground. To determine the shorted components while observing TRD, unplug the TR and determine if the short goes away. If the short is still present unplug the transmission harness and determine if the short goes away. If the short is still present, then the short is in the PCM or vehicle harness. Remove the suspect circuit(s) wire terminal from the PCM connector. If the short is still present, then the PCM has an internal failure, otherwise the failure is in the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5132 Transmission Position Switch/Sensor: Adjustments Transmission Range (TR) Sensor Adjustment Special Tool(s) Adjust 1. With the vehicle in NEUTRAL, position it on a hoist For additional information, refer to Maintenance/Service and Repair. 2. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the connector. 4. Disconnect the digital transmission range (TR) sensor electrical connector. 5. Remove the range selector lever cable end from the manual control lever. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5133 6. Remove the outer manual control lever. 7. Loosen but do not remove the digital TR sensor screws. 8. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. ^ Tighten to 8 Nm (71 inch lbs.) 9. Install the outer manual lever. ^ Tighten to 48 Nm (35 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5134 10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable end onto the manual control lever. 11. Reconnect the digital TR sensor electrical connector. 12. Move the rubber boot back over the connector. 13. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5135 14. Verify that the selector lever cable is adjusted correctly. 15. Verify that the vehicle will start in PARK and NEUTRAL and that the reverse lamps illuminate in REVERSE. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5136 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the connector. 4. Disconnect the digital transmission range (TR) sensor electrical connector. 5. Remove the selector lever cable from the manual control lever. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5137 6. Remove the outer manual control lever. 7. Remove the digital TR sensor. Installation 1. CAUTION: The digital transmission range sensor must fit flush against the boss on the case to prevent damage to the sensor. Install the digital TR sensor and 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 be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5138 ^ Tighten to 8 Nm (71 inch lbs.) 3. Install the outer manual lever. ^ Tighten to 48 Nm (35 ft. lbs.) 4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable to the manual control lever. 5. Connect the digital TR sensor electrical connector. 6. Move the rubber boot back over the connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5139 7. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. 8. Verify that the selector lever cable is adjusted correctly. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Locations Transmission Pressure Test Port: Locations Air Pressure Tests Air Pressure Tests Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 5147 View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 5148 View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5151 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5152 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5153 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5154 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5155 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5156 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5157 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5158 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5159 Transmission Speed Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5160 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5161 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5162 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5163 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5164 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5165 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5166 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5167 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5168 Transmission Speed Sensor: Connector Views C193 C143 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5169 C164 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 5172 6. Remove the selector lever cable and bracket. 7. Disconnect the turbine shaft speed (TSS) sensor electrical connector. 8. Remove the TSS sensor. 1 Remove the TSS sensor screw. 2 Remove the TSS sensor from the transmission. ^ Inspect the TSS sensor O-ring for damage. If damaged, install a new O-ring. Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the TSS sensor into the transmission. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 5173 2 Tighten the TSS sensor screw. ^ Tighten to 14 Nm (10 ft. lbs.) 2. Connect the TSS sensor electrical connector. 3. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable and bracket. ^ Tighten to 40 Nm (30 ft. lbs.) 4. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 5174 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Install the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 ft. lbs.) 7. Install the front driveshaft to the front differential. ^ Tighten to 18 Nm (13 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 5175 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 5176 6. Remove the selector lever cable and bracket. 7. Disconnect the heated oxygen sensor (HO2S) sensor connector from the transmission case. 8. Disconnect the output shaft speed (OSS) sensor electrical connector. 9. Remove the 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, install a new O-ring. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 5177 Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the OSS sensor into the transmission. 2 Tighten the OSS sensor screw. ^ Tighten to 14 Nm (10 ft. lbs.) 2. Connect the OSS sensor electrical connector. 3. Connect the HO2S connector to the transmission case. 4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 5178 cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable and bracket. ^ Tighten to 40 Nm (30 ft. lbs.) 5. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. 4WD vehicles 6. Install the front driveshaft in the vehicle. 7. Install the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 5179 8. Install the front driveshaft to the front differential. ^ Tighten to 18 Nm (13 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 5180 Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor Intermediate Shaft Speed Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 5181 6. Remove the selector lever cable and bracket. 7. Disconnect the intermediate shaft speed sensor electrical connector. 8. Remove the intermediate shaft speed sensor. 1 Remove the intermediate shaft speed sensor screw. 2 Remove the intermediate shaft speed sensor from the transmission. ^ Inspect the intermediate shaft speed sensor O-ring for damage. If damaged, install a new O-ring. Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the intermediate shaft speed sensor into the transmission. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 5182 2 Tighten the intermediate shaft speed sensor screw. ^ Tighten to 14 Nm (10 ft. lbs.) 2. Connect the intermediate shaft speed sensor electrical connector. 3. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable and bracket. ^ Tighten to 40 Nm (30 ft. lbs.) 4. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 5183 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Install the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 ft. lbs.) 7. Install the front driveshaft to the front differential. ^ Tighten to 18 Nm (13 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5188 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5189 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5190 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5191 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5192 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5193 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5194 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5195 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5196 Transmission Temperature Sensor/Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5197 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5198 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5199 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5200 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5201 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5202 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5203 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5204 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 07-6-3 > Apr > 07 > A/T 'Wrench Lamp' ON/Multiple DTC's Set In TCM Valve Body: Customer Interest A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM TSB 07-6-3 04/02/07 6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac MERCURY: 2006-2007 Mountaineer ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition vehicles may exhibit the following diagnostic trouble codes in the transmission control module (1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657, P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083, P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination at the mechatronic assembly. ACTION Follow the Service Procedure steps to correct the condition. NOTE IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM BARRIER STRIP. SERVICE PROCEDURE Remove the source of contamination from the transmission control unit (TCU)/solenoid connections and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent recurrence. 1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01. 2. Remove the six (6) long fasteners from the TCM unit. (Figure 1) 3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of the main control during this procedure. NOTE IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS SYSTEM. 4. Inspect the TCM at the following locations for metal chips or other metallic contamination. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 07-6-3 > Apr > 07 > A/T 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5213 a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination. (Figure 2) b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure 3 and 4) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 07-6-3 > Apr > 07 > A/T 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5214 c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure 5) 5. Prior to installation of the protective strip, remove all machining chips and or other metallic contamination from these areas with a clean, lint free cloth. 6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam barrier strip is installed). 7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first, "point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM, Section 307-01. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 07-6-3 > Apr > 07 > A/T 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5215 8. Reinstall the mechatronic assembly following the WSM, Section 307-01. 9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01. 10. Set the transmission fluid level following the WSM, Section 307-01. 11. Clear all DTC(s) from the TCM. 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 070603A 2006-2007 2.6 Hrs. Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) 070603A 2007 Expedition 6R75 2.7 Hrs. Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) DEALER CODING CONDITION BASIC PART NO. CODE 14B167 49 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM Valve Body: All Technical Service Bulletins A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM TSB 07-6-3 04/02/07 6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac MERCURY: 2006-2007 Mountaineer ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition vehicles may exhibit the following diagnostic trouble codes in the transmission control module (1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657, P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083, P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination at the mechatronic assembly. ACTION Follow the Service Procedure steps to correct the condition. NOTE IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM BARRIER STRIP. SERVICE PROCEDURE Remove the source of contamination from the transmission control unit (TCU)/solenoid connections and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent recurrence. 1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01. 2. Remove the six (6) long fasteners from the TCM unit. (Figure 1) 3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of the main control during this procedure. NOTE IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS SYSTEM. 4. Inspect the TCM at the following locations for metal chips or other metallic contamination. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5221 a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination. (Figure 2) b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure 3 and 4) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5222 c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure 5) 5. Prior to installation of the protective strip, remove all machining chips and or other metallic contamination from these areas with a clean, lint free cloth. 6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam barrier strip is installed). 7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first, "point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM, Section 307-01. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5223 8. Reinstall the mechatronic assembly following the WSM, Section 307-01. 9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01. 10. Set the transmission fluid level following the WSM, Section 307-01. 11. Clear all DTC(s) from the TCM. 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 070603A 2006-2007 2.6 Hrs. Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) 070603A 2007 Expedition 6R75 2.7 Hrs. Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) DEALER CODING CONDITION BASIC PART NO. CODE 14B167 49 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5224 Valve Body: Locations Main Control Valve Body Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5225 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5226 Valve Body: Diagrams Main Control Valve Body Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5227 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement Valve Body: Removal and Replacement Main Control Valve Body Main Control Valve Body Special Tool(s) Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. If equipped, remove the drain plug and drain the fluid. 3. NOTE: Clean the area around the connector to prevent contamination of the solenoid body connector. Disconnect the solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage. If not damaged, the gasket should be reused. Remove the 16 transmission fluid pan screws, fluid pan and gasket. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5230 5. Remove the transmission fluid filter. 6. Remove the reverse servo. 7. Remove the solenoid body. 8. Remove the manual control valve detent spring. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5231 9. Remove the main control valve body. Installation 1. Install the special tools into the transmission case. 2. Using the special tools, install the main control valve body and loosely install the screws. 1 Install the short screw. 2 Install the screw with the larger head. 3 Install the remaining screws. 3. Remove the special tools and loosely install the screw. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5232 4. Tighten the screws in the sequence shown. ^ Tighten to 10 Nm (89 inch lbs.) 5. Install the manual control valve detent spring. ^ Tighten to 10 Nm (89 inch lbs.) 6. Install the reverse servo. Tighten the screws in 2 stages, in the sequence shown. ^ Stage 1: Tighten to 5 Nm (44 inch lbs.) ^ Stage 2: Tighten to 11 Nm (8 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5233 7. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean automatic transmission fluid. 8. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If it is damaged, transmission leak may occur. Install the solenoid body. Tighten the bolts in the sequence shown. ^ Tighten to 8 Nm (71 inch lbs.) 9. CAUTION: Damage may occur to fluid filter seals if they are not lubricated with clean automatic transmission fluid. NOTE: Make sure that the fluid filter seals are correctly seated on the filter. Lubricate the seals and install the transmission fluid filter. ^ Tighten to 10 Nm (89 inch lbs.) 10. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the gasket should be reused. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5234 Install the fluid pan gasket on the pan. 11. Install the transmission fluid pan and gasket and loosely install the screws. 12. Tighten the screws in a crisscross sequence. ^ Tighten to 11 Nm (8 ft. lbs.) 13. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above specification. NOTE: Always install new O-ring seals on vehicle harness connector. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission connector and connect the connector. ^ Tighten to 5 Nm (44 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5235 14. Fill the transmission. Solenoid Body Assembly Solenoid Body Assembly Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the drain plug and drain the fluid. 3. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. Disconnect the solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the gasket should be reused. Remove the 16 transmission fluid pan screws, fluid pan and gasket. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5236 5. Remove the transmission fluid filter. 6. CAUTION: Do not damage the solenoid body connector pins. Remove the solenoid body bolts and remove the solenoid body by pulling down on the solenoid body and pushing down on the connector from the other side of the case. Installation 1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean automatic transmission fluid. 2. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur. Install the solenoid body. Tighten the bolts in sequence shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5237 ^ Tighten to 8 Nm (71 inch lbs.) 3. CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be damaged. NOTE: Make sure that the fluid filter seals are correctly seated on the filter. Lubricate the seals and install the transmission fluid filter. ^ Tighten to 10 Nm (89 inch lbs.) 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage, if not damaged, the gasket should be reused. Install the transmission fluid pan and gasket and loosely install the screws. 5. Tighten the screws in a crisscross sequence. ^ Tighten to 11 Nm (8 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5238 6. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the specification. NOTE: Always install new O-ring seals on vehicle harness connector. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission connector and connect the connector. ^ Tighten to 5 Nm (44 inch lbs.) 7. Fill the transmission. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5239 Valve Body: Overhaul Main Control Valve Body Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5240 Disassembly 1. NOTE: The valve body separator plate has a bonded gasket. Do not reuse. Discard the plate. Remove and discard the valve body separator plate. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5241 2. Remove the check balls. 3. NOTE: Refer to the disassembled view. Disassemble the main control valve body only if cleaning is required. Assembly 1. CAUTION: Do not lose parts when cleaning or repairing. Thoroughly clean all parts in solvent and blow dry with moisture-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: ^ 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 distortion ^ Inspect all springs for distortion ^ 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 check for a bent condition 3. Assemble the main control valve body. 4. Install the main control valve body check balls. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 5242 5. NOTE: Use a new valve body separator plate for main control valve body installation. Using the special tools, install a new main control valve body separator plate. ^ Tighten to 7 Nm (62 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 09-22-15 > Nov > 09 > A/T Controls - MIL ON/Various A/T Solenoid DTC's Wiring Harness: Customer Interest A/T Controls - MIL ON/Various A/T Solenoid DTC's TSB 09-22-15 11/16/09 5R555 TRANSMISSION - CHECK ENGINE LIGHT ON - VARIOUS DTC'S - WATER INTRUSION FROM A/C DRAIN INTO TRANSMISSION SOLENOID BODY CONNECTOR - BUILT ON OR BEFORE 8/12/2009 FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Sport Trac vehicles built on or before 8/12/2009 and equipped with 5R55S transmission may exhibit a check engine light with diagnostic trouble code DTC P0713 and/or various transmission solenoid body connector related DTCs. This may be due to water traveling down from the A/C drain into the solenoid body connector on the left side of the transmission. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Verify any transmission related symptoms or transmission related DTC's that are present. 2. Check the transmission solenoid connector for signs of water intrusion, corrosion, that may be coming from the A/C drain. (Figure 1) 3. If present, clean the connector thoroughly and apply Motorcraft(R) Electrical Grease as needed. 4. Cut and install patch kit over the connector. (Figure 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 09-22-15 > Nov > 09 > A/T Controls - MIL ON/Various A/T Solenoid DTC's > Page 5251 Parts Block 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 092215A 2006-2010 Explorer, 0.4 Hr. Mountaineer 2007-2010 Explorer Sport Trac 4.0L: Check DTCs, Inspect, Clean, And Grease Connector, Install Patch (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7G391 X2 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-22-15 > Nov > 09 > A/T Controls - MIL ON/Various A/T Solenoid DTC's Wiring Harness: All Technical Service Bulletins A/T Controls - MIL ON/Various A/T Solenoid DTC's TSB 09-22-15 11/16/09 5R555 TRANSMISSION - CHECK ENGINE LIGHT ON - VARIOUS DTC'S - WATER INTRUSION FROM A/C DRAIN INTO TRANSMISSION SOLENOID BODY CONNECTOR - BUILT ON OR BEFORE 8/12/2009 FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Sport Trac vehicles built on or before 8/12/2009 and equipped with 5R55S transmission may exhibit a check engine light with diagnostic trouble code DTC P0713 and/or various transmission solenoid body connector related DTCs. This may be due to water traveling down from the A/C drain into the solenoid body connector on the left side of the transmission. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Verify any transmission related symptoms or transmission related DTC's that are present. 2. Check the transmission solenoid connector for signs of water intrusion, corrosion, that may be coming from the A/C drain. (Figure 1) 3. If present, clean the connector thoroughly and apply Motorcraft(R) Electrical Grease as needed. 4. Cut and install patch kit over the connector. (Figure 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-22-15 > Nov > 09 > A/T Controls - MIL ON/Various A/T Solenoid DTC's > Page 5257 Parts Block 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 092215A 2006-2010 Explorer, 0.4 Hr. Mountaineer 2007-2010 Explorer Sport Trac 4.0L: Check DTCs, Inspect, Clean, And Grease Connector, Install Patch (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7G391 X2 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Hydraulic Hose, Clutch > Component Information > Tools and Equipment Hydraulic Hose: Tools and Equipment Clutch Line Fork AST tool# 8008 Used for the R and R of the hydraulic clutch line from the internally mounted slave cylinder. This tool is applicable to the following Ford vehicles with manual transmissions: 1989 and later Ford Aerostar, Bronco II, Explorer, F150 and Ranger. - For R and R of Hydraulic Clutch Lines - Applicable to Ford Models with Manual Transmissions - Steel Construction - Black-Oxide Finish Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity Refill ..................................................................................................................................................... ........................................................... 3.5 pts. (1.7L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 5267 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Type ................................................................................................................................. SAE 75W-140 High Performance Synthetic Rear Axle Lubricant Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Page 5268 Fluid - Differential: Service and Repair Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear Differential Draining and Filling Special Tool(s) Material Fluid Check 1. NOTE: Before removing, clean the area around the filler plug. Remove the fill plug. Fluid Drain and Fill 1. Remove the drain plug. 2. Clean and install the drain plug. ^ Tighten to 34 Nm (25 ft. lbs.) 3. Fill the axle to the bottom of the fill plug hole. 4. Install the fill plug. ^ Tighten to 34 Nm (25 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair Differential Output Shaft Bearing: Service and Repair Stub Shaft Pilot Bearing and Seal Special Tool(s) Material Removal 1. Remove the halfshaft assembly. 2. NOTE: If removing the stub shaft pilot bearing oil seal only, engage the tangs of the special tool on the stub shaft pilot bearing oil seal. Using the special tools, remove the stub shaft pilot bearing and stub shaft pilot bearing oil seal. 1 Firmly engage the tangs of the special tool on the stub shaft pilot bearing. 2 Remove the stub shaft pilot bearing and stub shaft pilot bearing oil seal. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Page 5273 3. Inspect the stub shaft pilot bearing oil seal journal for rust, nicks and scratches. Polish the seal journal surface with fine crocus cloth, if necessary. Installation 1. Using rear axle lubricant, lubricate the new stub shaft pilot bearing. 2. CAUTION: Installation of the stub shaft pilot bearing or stub shaft pilot bearing oil seal without the correct tools can result in early stub shaft pilot bearing or stub shaft pilot bearing oil seal failure. If the stub shaft pilot bearing becomes cocked in the bore during installation, remove it and install a new stub shaft pilot bearing. Place the stub shaft pilot bearing onto the special tools. 3. Install the stub shaft pilot bearing into the rear axle housing bore. 4. NOTE: Do not disassemble the new oil seal. NOTE: Use a tool like the Lisle LIS 17850 to avoid interference with the suspension components. Install the stub shaft pilot bearing oil seal onto a suitable seal installer. 5. Carefully align the stub shaft pilot bearing oil seal with the housing bore and install the stub shaft pilot bearing oil seal flush in the differential housing. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Service and Repair > Page 5274 6. Remove and discard the halfshaft excluder seal, if equipped. 7. Install the halfshaft assembly. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair Pinion Flange: Service and Repair Drive Pinion Flange and Drive Pinion Seal Special Tool(s) Material Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Page 5278 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the rear wheel and tire assemblies. 3. CAUTION: Remove the rear brake calipers to prevent drag during the 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 silicone brake caliper grease or equivalent for re-lubing the caliper slide pins. Other greases can swell the guide pin boots, resulting in contamination and accelerated corrosion and wear of the caliper slide pin mechanism. CAUTION: Do not allow the calipers to hang from the brake hoses. Remove the rear disc brake caliper assembly. 1 Remove the disc brake caliper bolts. 2 Lift the rear disc brake caliper off the knuckle. ^ Support the caliper assembly with a length of mechanic's wire. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Page 5279 4. Index-mark the driveshaft flange and pinion flange for correct alignment during installation. 5. NOTE: If new driveshaft flange bolts are not available, coat the threads of the original driveshaft flange bolts with Threadlock and sealer. Remove the driveshaft flange bolts. 6. CAUTION: The driveshaft flange fits tightly on the 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 pinion flange, then using mechanic's wire, position the driveshaft aside. 7. Install a Nm (inch pound) torque wrench on the pinion nut and record the torque necessary to maintain rotation of the drive pinion gear through several revolutions. 8. Using the special tool to hold the pinion flange, remove and discard the pinion nut. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Page 5280 9. Index-mark the pinion flange and drive pinion gear to maintain initial balance during installation. 10. Using the special tool, remove the pinion flange. 11. If necessary, use a screwdriver to force up the metal flange of the pinion seal. Install gripping pliers and strike with a hammer to remove the drive pinion seal. Installation 1. If removed, lubricate the lips of the new drive pinion seal with grease. 2. CAUTION: If the drive pinion seal becomes misaligned during installation, remove the drive pinion seal and install a new drive pinion seal. NOTE: Always install a new drive pinion seal when removed. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Page 5281 If the drive pinion seal was removed, use the special tool to install a new drive pinion seal. 3. Inspect the pinion flange seal journal for rust, nicks and scratches prior to installing the pinion flange. Polish the seal journal with fine crocus cloth, if necessary. 4. Lubricate the pinion flange splines with grease. 5. NOTE: Disregard the index marks if installing a new pinion flange. Position the pinion flange. 6. Using the special tools, install the pinion flange. 7. CAUTION: Do not under any circumstance loosen the pinion nut to reduce drive pinion bearing preload. If it is necessary to reduce drive pinion bearing preload, install a new differential drive pinion collapsible spacer and pinion nut. Tighten the pinion nut to set the drive pinion bearing preload. ^ Rotate the drive pinion gear occasionally to make sure the drive pinion bearings seat correctly. Take frequent drive pinion bearing preload readings by rotating the drive pinion gear with a Nm (inch pound) torque wrench. ^ Rotational torque must be at least the recorded original torque plus a maximum of 5 inch-pounds. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Page 5282 8. CAUTION: To prevent interference with the rear disc brake caliper operation, install only the correct disc brake caliper bolt. NOTE: Make sure the stainless steel shoe slippers are correctly positioned. Install new slippers if worn or damaged. NOTE: Use the brake disc pad spreader to spread pads for reassembly. Install the disc brake caliper, then install the disc brake caliper bolts. ^ Tighten to 32 Nm (24 ft. lbs.) 9. CAUTION: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. To make sure that the yoke seats squarely on the pinion flange, tighten the driveshaft flange bolts evenly in a cross-pattern as shown. CAUTION: If new driveshaft flange bolts are not available, coat the threads of the original driveshaft flange bolts with Threadlock and sealer. Install the driveshaft, then the driveshaft flange bolts. ^ Tighten the bolts in the order shown to 112 Nm (83 ft. lbs.) 10. Install the rear wheel and tire assemblies. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal Seals and Gaskets: Service and Repair Drive Pinion Flange and Drive Pinion Seal Drive Pinion Flange and Drive Pinion Seal Special Tool(s) Material Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal > Page 5287 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the rear wheel and tire assemblies. 3. CAUTION: Remove the rear brake calipers to prevent drag during the 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 silicone brake caliper grease or equivalent for re-lubing the caliper slide pins. Other greases can swell the guide pin boots, resulting in contamination and accelerated corrosion and wear of the caliper slide pin mechanism. CAUTION: Do not allow the calipers to hang from the brake hoses. Remove the rear disc brake caliper assembly. 1 Remove the disc brake caliper bolts. 2 Lift the rear disc brake caliper off the knuckle. ^ Support the caliper assembly with a length of mechanic's wire. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal > Page 5288 4. Index-mark the driveshaft flange and pinion flange for correct alignment during installation. 5. NOTE: If new driveshaft flange bolts are not available, coat the threads of the original driveshaft flange bolts with Threadlock and sealer. Remove the driveshaft flange bolts. 6. CAUTION: The driveshaft flange fits tightly on the 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 pinion flange, then using mechanic's wire, position the driveshaft aside. 7. Install a Nm (inch pound) torque wrench on the pinion nut and record the torque necessary to maintain rotation of the drive pinion gear through several revolutions. 8. Using the special tool to hold the pinion flange, remove and discard the pinion nut. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal > Page 5289 9. Index-mark the pinion flange and drive pinion gear to maintain initial balance during installation. 10. Using the special tool, remove the pinion flange. 11. If necessary, use a screwdriver to force up the metal flange of the pinion seal. Install gripping pliers and strike with a hammer to remove the drive pinion seal. Installation 1. If removed, lubricate the lips of the new drive pinion seal with grease. 2. CAUTION: If the drive pinion seal becomes misaligned during installation, remove the drive pinion seal and install a new drive pinion seal. NOTE: Always install a new drive pinion seal when removed. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal > Page 5290 If the drive pinion seal was removed, use the special tool to install a new drive pinion seal. 3. Inspect the pinion flange seal journal for rust, nicks and scratches prior to installing the pinion flange. Polish the seal journal with fine crocus cloth, if necessary. 4. Lubricate the pinion flange splines with grease. 5. NOTE: Disregard the index marks if installing a new pinion flange. Position the pinion flange. 6. Using the special tools, install the pinion flange. 7. CAUTION: Do not under any circumstance loosen the pinion nut to reduce drive pinion bearing preload. If it is necessary to reduce drive pinion bearing preload, install a new differential drive pinion collapsible spacer and pinion nut. Tighten the pinion nut to set the drive pinion bearing preload. ^ Rotate the drive pinion gear occasionally to make sure the drive pinion bearings seat correctly. Take frequent drive pinion bearing preload readings by rotating the drive pinion gear with a Nm (inch pound) torque wrench. ^ Rotational torque must be at least the recorded original torque plus a maximum of 5 inch-pounds. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal > Page 5291 8. CAUTION: To prevent interference with the rear disc brake caliper operation, install only the correct disc brake caliper bolt. NOTE: Make sure the stainless steel shoe slippers are correctly positioned. Install new slippers if worn or damaged. NOTE: Use the brake disc pad spreader to spread pads for reassembly. Install the disc brake caliper, then install the disc brake caliper bolts. ^ Tighten to 32 Nm (24 ft. lbs.) 9. CAUTION: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. To make sure that the yoke seats squarely on the pinion flange, tighten the driveshaft flange bolts evenly in a cross-pattern as shown. CAUTION: If new driveshaft flange bolts are not available, coat the threads of the original driveshaft flange bolts with Threadlock and sealer. Install the driveshaft, then the driveshaft flange bolts. ^ Tighten the bolts in the order shown to 112 Nm (83 ft. lbs.) 10. Install the rear wheel and tire assemblies. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal > Page 5292 Seals and Gaskets: Service and Repair Stub Shaft Pilot Bearing and Seal Stub Shaft Pilot Bearing and Seal Special Tool(s) Material Removal 1. Remove the halfshaft assembly. 2. NOTE: If removing the stub shaft pilot bearing oil seal only, engage the tangs of the special tool on the stub shaft pilot bearing oil seal. Using the special tools, remove the stub shaft pilot bearing and stub shaft pilot bearing oil seal. 1 Firmly engage the tangs of the special tool on the stub shaft pilot bearing. 2 Remove the stub shaft pilot bearing and stub shaft pilot bearing oil seal. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal > Page 5293 3. Inspect the stub shaft pilot bearing oil seal journal for rust, nicks and scratches. Polish the seal journal surface with fine crocus cloth, if necessary. Installation 1. Using rear axle lubricant, lubricate the new stub shaft pilot bearing. 2. CAUTION: Installation of the stub shaft pilot bearing or stub shaft pilot bearing oil seal without the correct tools can result in early stub shaft pilot bearing or stub shaft pilot bearing oil seal failure. If the stub shaft pilot bearing becomes cocked in the bore during installation, remove it and install a new stub shaft pilot bearing. Place the stub shaft pilot bearing onto the special tools. 3. Install the stub shaft pilot bearing into the rear axle housing bore. 4. NOTE: Do not disassemble the new oil seal. NOTE: Use a tool like the Lisle LIS 17850 to avoid interference with the suspension components. Install the stub shaft pilot bearing oil seal onto a suitable seal installer. 5. Carefully align the stub shaft pilot bearing oil seal with the housing bore and install the stub shaft pilot bearing oil seal flush in the differential housing. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Drive Pinion Flange and Drive Pinion Seal > Page 5294 6. Remove and discard the halfshaft excluder seal, if equipped. 7. Install the halfshaft assembly. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Specifications > Mechanical Specifications Axle Shaft Assembly: Mechanical Specifications General Specifications General Specifications General Specifications Torque Specifications Torque Specifications Torque Specifications Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Specifications > Mechanical Specifications > Page 5300 Axle Shaft Assembly: Capacity Specifications Axle Lubricants and Capacities Axle Lubricants and Capacities Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Specifications > Mechanical Specifications > Page 5301 Axle Shaft Assembly: Fluid Type Specifications Axle Lubricants and Capacities Axle Lubricants and Capacities Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Specifications > Page 5302 Axle Shaft Assembly: Description and Operation Rear Drive Halfshafts ^ The RH and LH halfshafts are different lengths, with the RH halfshaft being the longer of the 2. ^ Inboard and outboard CV joints connect to a splined shaft. A circlip stopper holds the inboard race assembly (inboard CV joint) together. ^ An axle circlip retains the splined inboard CV joint to the differential side gear. Install a new axle circlip every time the halfshaft is removed from the vehicle. ^ A rear axle wheel end nut secures the side shaft assembly (interconnecting shaft and outboard CV joint) to the rear hub. Install a new rear axle wheel end nut every time you remove the halfshaft from the vehicle. ^ Install a new differential stub shaft seal every time the halfshaft is removed. Halfshaft Handling CAUTION: Never pick up or hold the halfshaft by the inboard or outboard CV joint only. NOTE: Only the inner CV joints are removable for installation of new CV boots and clamps. The boots and clamps are the only serviced parts of the halfshaft assembly. Handle all halfshaft components carefully during removal and installation procedures. ^ The halfshaft assemblies are not repairable. Install new assemblies if worn/damaged. ^ To separate the halfshaft from the rear hub, press the outboard CV joint from the rear hub. ^ To separate the halfshaft from the differential, apply a load to the back face of the inboard CV joint assembly to overcome the axle circlip. ^ Do not overangle the CV joints. ^ Damage will occur to an assembled inboard CV joint if it is overplunged outward from the joint housing. ^ Never use a hammer to remove or install the halfshafts. ^ Never use the halfshaft assembly as a lever to position other components. Always support the free end of the halfshaft. ^ Do not allow the boots to contact sharp edges or hot exhaust components. ^ Handle the halfshaft by the interconnecting shaft only to avoid pull-apart and potential damage to the CV joints. ^ Do not drop assembled halfshafts. The impact can cut the boots from the inside without evidence of external damage. Wheel and Tire Balancing, Rear WARNING: Do not balance the rear wheels and tires while mounted on the vehicle. Hoisting CAUTION: Use a frame-contact hoist only. Vehicle or component damage can result if other types of hoists are used. For additional information, refer to Maintenance/Service and Repair. Never raise the vehicle using the halfshafts as lift points. Undercoating and Rustproofing During undercoating and rustproofing procedures, protect the boots from the coating materials. Foreign materials on the rubber boots will cause extreme advanced wear. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement Axle Shaft Assembly: Removal and Replacement Halfshaft Special Tool(s) Material Removal and Installation 1. CAUTION: Do not loosen the rear axle wheel end nut until after the wheel and tire assembly are removed from the vehicle. Wheel bearing damage will occur if the wheel bearing is unloaded with the weight of the vehicle applied. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the rear wheel and tire assembly. 3. Remove and discard the rear axle wheel end nut. ^ To install, tighten to 275 Nm (203 ft. lbs.) 4. CAUTION: Do not use a hammer to separate the rear axle halfshaft assembly from the hub. Damage to the threads and internal CV joint components can result. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5305 Using the special tool, press the outboard CV joint until it is loose in the hub. 5. Remove the brake cable retainer screw. ^ To install, tighten to 20 Nm (15 ft. lbs.) 6. Remove and discard the outboard toe link nut and back out the bolt for clearance. ^ To install, tighten to 350 Nm (259 ft. lbs.) at curb ride height. 7. Remove and discard the lower arm outboard bolt. ^ To install, tighten to 275 Nm (203 ft. lbs.) at curb ride height. 8. Remove and discard the 3 wheel knuckle bolts. ^ To install, tighten to 275 Nm (203 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5306 9. Pivot the wheel knuckle assembly upward on the upper arm outboard bolt. ^ Loosen the upper arm bolt to prevent bushing damage. ^ To install, tighten to 275 Nm (203 ft. lbs.) at curb ride height. 10. CAUTION: Do not damage the stub shaft pilot bearing oil seal or the machined sealing surface on the inboard CV joint housing. CAUTION: Do not allow the splines on the inboard CV joint housing to touch the stub shaft pilot bearing oil seal. NOTE: A circlip retains the inboard CV joint housing to the differential side gear in the axle. Using the special tool, disengage the inboard CV joint housing from the differential side gear. 11. Remove the halfshaft assembly. 12. CAUTION: Do not tighten the rear wheel hub nut with the vehicle on the ground. The nut must be tightened to specification before the vehicle is lowered onto the wheels. Wheel bearing damage will occur if the wheel bearing is loaded with the weight of the vehicle applied. CAUTION: Install and tighten the new axle wheel end nut to specification in a continuous rotation. Stopping the rotation during installation will cause the nylon lock to seat incorrectly. This will cause incorrect torque readings while tightening the axle wheel end nut and lead to bearing failure. Always install a new axle wheel end nut, after loosening or when not tightened to specifications, in a continuous rotation. CAUTION: Always install a new differential stub shaft seal whenever the halfshaft is removed. CAUTION: Install a new circlip every time the halfshaft is removed from the axle. NOTE: Start one end of the circlip in the groove and work the circlip over the halfshaft and into the groove to prevent the circlip from Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5307 overexpanding. NOTE: Apply the brake to keep the halfshaft from rotating. To install, reverse the removal procedure. 13. Carry out a rear wheel alignment. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5308 Axle Shaft Assembly: Overhaul Halfshaft Joint Special Tool(s) Material Disassembly 1. Remove the halfshaft assembly. 2. For the inboard CV joint: 1 Remove and discard the boot clamps. 2 Remove the inboard CV joint housing. 3. For the inboard CV joint: 1 Remove and discard the retainer circlip. 2 Slide the boot away from the CV joint. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5309 4. Using a suitable 3-jaw puller, remove the CV joint. 5. Remove and discard the tri-lobe insert and the boot. 6. NOTE: The outboard CV joint is not removable from the halfshaft. The boot must be removed or installed from the inboard CV joint side of the shaft. For the outboard CV joint: 1 Remove and discard the boot clamps. 2 Remove and discard the boot. Assembly 1. For the outboard CV joint: 1 Slide the boot on the interconnecting shaft. 2 Pack the outboard CV joint with 225 grams (7.93 oz.) of grease. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5310 3 Spread any remaining grease evenly inside the boot. 4 Install the boot by seating it in the groove in the CV joint housing. 2. Using the special tool, install the boot clamps. 3. CAUTION: Install a new circlip every time the halfshaft is removed from the axle. CAUTION: Start one end of the circlip in the groove and work the circlip over the halfshaft and into the groove to prevent the circlip from overexpanding. Install a new retainer circlip. 4. Remove and discard the inboard halfshaft excluder seal, if equipped. 5. For the inboard CV joint: Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5311 1 Position the clamp on the interconnecting shaft. 2 Position the boot on the interconnecting shaft. 3 Install the tri-lobe insert. 6. Using the special tool, install the CV joint. 7. Install the retainer circlip. 8. For the inboard CV joint: 1 Pack the inboard CV joint housing with 250 grams (8.82 oz.) of grease. 2 Spread any remaining grease evenly inside the boot and CV joint. 3 Install the inboard CV joint housing, seating the boot in the groove in the housing. 9. Set the halfshaft assembled length to specifications. 1 Measure the entire assembly length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 5312 2 Push in or pull out on the inner joint as necessary to adjust the halfshaft assembled length. 3 Hold the inner joint to prevent the assembled length from changing, and insert a soft, flat tool between the boot and the joint to equalize the pressure. 10. Using the special tool, install both boot clamps. 11. Install the halfshaft assembly. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-19-3 > Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking Seals and Gaskets: Customer Interest Drivetrain - Rear Axle Seal(s) Leaking TSB 08-19-3 09/29/08 UNITIZED SEAL DIAGNOSIS - LEAK / GREASE OIL SEPARATION - AXLE BEARING SEAL 8.8 IFS, 8.8 IRS, AND 9.75 IRS AXLES FORD: 2002-2008 Explorer 2003-2008 Expedition 2006-2008 Explorer Sport Trac LINCOLN: 2003-2005 Aviator 2003-2008 Navigator MERCURY: 2002-2008 Mountaineer This article supersedes TSB 06-22-05 to update the model years, Part List and Service Procedure. ISSUE Some 2006-2008 Expedition, Navigator, Explorer, Explorer Sport Track, and Mountaineer vehicles equipped with rear axle unitized cartridge seal, 2007-2008 Expedition-Navigator AWD equipped with front and rear axle unitized cartridge seal. 2003-2005 Expedition-Navigator, 2002-2005, Explorer-Mountaineer, 2003-2005 Aviator equipped with unitized cartridge rear axle seal, may exhibit oil separation from the internal lube found in the unitized cartridge seal. This oil separation appears to be, and is often misdiagnosed, as an axle lube leak. The majority of the vehicles with this condition will be located in northern Canada and Alaska due to the extreme cold weather. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE DO NOT REPLACE THE UNITIZED CARTRIDGE SEAL UNTIL YOU COMPLETE THIS DIAGNOSTIC SERVICE PROCEDURE. FAILURE TO PROPERLY DIAGNOSE THE ISSUE MAY RESULT IN UNNECESSARILY REPLACING THE SEAL, RESULTING IN A REPEAT CONCERN. NOTE THIS DIAGNOSTIC PROCEDURE IS ONLY NECESSARY ON VEHICLES WITH THE NEW UNITIZED CARTRIDGE SEAL. THIS SEAL HAS BEEN USED IN PRODUCTION FROM 2006 MODEL YEAR TO PRESENT, HOWEVER, SOME VEHICLES BUILT PRIOR TO 2006 MODEL YEAR MAY HAVE THIS NEW UPDATED UNITIZED CARTRIDGE SEAL INSTALLED AS A SERVICE REPAIR. 1. Raise vehicle, refer to Workshop Manual (WSM), Section 100-02. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-19-3 > Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking > Page 5321 NOTE IF SEAL IS OLD DESIGN RADIAL LIP SEAL STYLE, (SEE FIGURES 1 AND 2 TO IDENTIFY RADIAL LIP SEAL) THERE IS NO INTERNAL GREASE PRESENT IN SEAL TO SEPARATE. THIS TSB DOES NOT APPLY. REFER TO WORKSHOP MANUAL DIAGNOSTIC. 2. Check axle half shaft seal to ensure that it is unitized cartridge design. 3. Clean axle housing around the seal area using Motorcraft® Metal Brake Parts Cleaner or equivalent cleaner. Wipe lube or oil with rag and let the housing dry. 4. Add 0.5 to 1 ounce (14.8 to 29.6 ml) Rotunda Dye-Lite® Leak Detection Dye for Gasoline Engine Oil 164-R3700, also contained in 164-R0756 to the axle following the appropriate Workshop Manual. NOTE ADDING THE DYE ON SOME VEHICLES WILL REQUIRE THE REAR WHEEL ABS SPEED SENSOR TO BE REMOVED. REFER TO THE APPROPRIATE WORKSHOP MANUAL DRAIN AND FILL PROCEDURE. 5. Road test vehicle a minimum distance 15 miles (24 km) at a minimum speed of 25 MPH (40 Km/h). NOTE A BRIGHT ORANGE AREA WILL IDENTIFY AXLE LUBE LEAK. FOR EXTREMELY SMALL OIL SEPARATION, ADDITIONAL AXLE OPERATION TIME MAY BE REQUIRED FOR THE LEAK TO APPEAR. 6. Raise vehicle to check for signs of leak. a. Use Rotunda 12V Master UV Leak Detector Kit 164-R0756 or equivalent to look for signs of leak. 7. If there is not a verifiable lube leak, clean axle near seal area and return the vehicle to the customer. NOTE IF THERE IS NO SIGNS OF LUBE LEAK, THIS MEANS THAT THE SUBSTANCE WHICH WAS PRESENT PRIOR TO THE PROCEDURE WAS OIL WHICH HAD SEPARATED FROM THE GREASE INTERNAL TO THE SEAL. THIS OIL IS A PRE-LUBE, AND IS NOT NECESSARY ONCE THE AXLE SEAL IS BROKEN IN. ONCE THE OIL SEPARATION HAS OCCURRED, THERE SHOULD BE NO Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-19-3 > Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking > Page 5322 FURTHER OIL SEPARATION FROM THE SEAL. REMOVING THE SEAL AND INSTALLING A NEW SEAL MIGHT CREATE A SITUATION WHERE THE OIL WILL SEPARATE, RESULTING IN THE SAME CONCERN. 8. If there is a verifiable axle lube leak, replace seal following the Workshop Manual (WSM), Section 205, or look at instruction sheet included in Axle Shaft Seal Kit. Parts Block 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 081903A 2003-2008 Expedition, 0.9 Hr. Navigator: INSPECT Axle Seal Leaks. Includes Time to Add Oil Dye and Road Test. This Labor Operation Can Be Claimed With Any Of The Labor Operations In This Article. (Do Not Use With 4139A, 4139A2) 081903A 2002-2008 Explorer, 0.7 Hr. Mountaineer, 2007-2008 Explorer Sport Trac, 2002-2005 Aviator: INSPECT Axle Seal Leaks. Includes Time to Add Oil Dye and Road Test. This Labor Operation Can Be Claimed With Any Of The Labor Operations In This Article. (Do Not Use With 4139A, 4139A2) 081903B 2003-2008 Expedition 1.3 Hrs. Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A, 4139A2) 081903C 2003-2008 Expedition 2.2 Hrs. Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A, 4139A2) 081903D 2003-2008 Expedition, 0.7 Hr. Navigator: Replace Rear Axle Stub Shaft Seal. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-19-3 > Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking > Page 5323 Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A, B, Or C (Do Not Use With 4139A, 4139A2) 081903D 2006-2008 Explorer, 1.1 Hrs. Mountaineer, 2007-2008 Explorer Sport Trac :Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) 081903D 2002-2005 Explorer, 0.9 Hr. Mountaineer:Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) 081903D 2003-2005 Aviator:Replace 0.8 Hr. Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) 081903E 2003-2008 Expedition, 1.2 Hrs. Navigator: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A, B, Or C (Do Not Use With 4139A, 4139A2) 081903E 2006-2008 Explorer, 2.1 Hrs. Mountaineer, 2007-2008 Explorer Sport Trac Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) 081903E 2002-2005 Explorer, 1.5 Hrs. Mountaineer: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A (Do Not Use With Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-19-3 > Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking > Page 5324 4139A, 4139A2) 081903E 2003-2005 Aviator: 1.6 Hrs. Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) DEALER CODING CONDITION BASIC PART NO. CODE 4A109 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-19-6 > Sep > 08 > Drivetrain - Rear Axle Squealing Noise Seals and Gaskets: Customer Interest Drivetrain - Rear Axle Squealing Noise TSB 08-19-6 09/29/08 HIGH PITCHED SQUEAL NOISE FROM THE REAR AXLE AREA - BUILT ON OR BEFORE 7/28/2008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer ISSUE Some 2006-2008 Explorer, Mountaineer and 2007-2008 Sport Trac vehicles built on or before 7/28/2008 may exhibit a high pitched squeal noise from the rear axle area while driving at low speeds. This may be caused by the rear outer axle halfshaft dust seals contacting the knuckle surface. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Position vehicle on a hoist and place it in neutral. 2. Remove the rear wheel and tire. For additional information, refer to Workshop Manual (WSM), Section 204-04. 3. Remove and discard the rear axle wheel end nut. To install, tighten to 203 lb-ft (275 N.m). (Figure 1) CAUTION DO NOT USE A HAMMER TO SEPARATE THE REAR AXLE HALFSHAFT ASSEMBLY FROM THE HUB. DAMAGE TO THE THREADS AND INTERNAL CONSTANT VELOCITY (CV) JOINT COMPONENTS MAY RESULT. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-19-6 > Sep > 08 > Drivetrain - Rear Axle Squealing Noise > Page 5329 4. Use the special tool, press the outboard constant velocity (CV) joint until it is loose in the hub. (Figure 2) 5. Use a brush and apply Motorcraft(R) Silicone Brake Caliper Grease and Dielectric Compound to lubricate the rear axle halfshaft dust seal. 6. Reverse steps 2 and 3 to install halfshaft, tire, and wheel. Parts Block 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 081906A 2006-2008 0.5 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Lubricate One Rear Constant Velocity Outboard Joint to Knuckle Dust Seal: 0.5 Hrs(Do Not Use With 4139A, 5968A) 081906B 2006-2008 0.9 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Lubricate Both Rear Constant Velocity Outboard Joint to Knuckle Dust Seal: 0.9 Hrs (Do Not Use With 4139A, 5968A) DEALER CODING CONDITION BASIC PART NO. CODE 1175 14 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-19-3 > Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking Seals and Gaskets: All Technical Service Bulletins Drivetrain - Rear Axle Seal(s) Leaking TSB 08-19-3 09/29/08 UNITIZED SEAL DIAGNOSIS - LEAK / GREASE OIL SEPARATION - AXLE BEARING SEAL 8.8 IFS, 8.8 IRS, AND 9.75 IRS AXLES FORD: 2002-2008 Explorer 2003-2008 Expedition 2006-2008 Explorer Sport Trac LINCOLN: 2003-2005 Aviator 2003-2008 Navigator MERCURY: 2002-2008 Mountaineer This article supersedes TSB 06-22-05 to update the model years, Part List and Service Procedure. ISSUE Some 2006-2008 Expedition, Navigator, Explorer, Explorer Sport Track, and Mountaineer vehicles equipped with rear axle unitized cartridge seal, 2007-2008 Expedition-Navigator AWD equipped with front and rear axle unitized cartridge seal. 2003-2005 Expedition-Navigator, 2002-2005, Explorer-Mountaineer, 2003-2005 Aviator equipped with unitized cartridge rear axle seal, may exhibit oil separation from the internal lube found in the unitized cartridge seal. This oil separation appears to be, and is often misdiagnosed, as an axle lube leak. The majority of the vehicles with this condition will be located in northern Canada and Alaska due to the extreme cold weather. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE DO NOT REPLACE THE UNITIZED CARTRIDGE SEAL UNTIL YOU COMPLETE THIS DIAGNOSTIC SERVICE PROCEDURE. FAILURE TO PROPERLY DIAGNOSE THE ISSUE MAY RESULT IN UNNECESSARILY REPLACING THE SEAL, RESULTING IN A REPEAT CONCERN. NOTE THIS DIAGNOSTIC PROCEDURE IS ONLY NECESSARY ON VEHICLES WITH THE NEW UNITIZED CARTRIDGE SEAL. THIS SEAL HAS BEEN USED IN PRODUCTION FROM 2006 MODEL YEAR TO PRESENT, HOWEVER, SOME VEHICLES BUILT PRIOR TO 2006 MODEL YEAR MAY HAVE THIS NEW UPDATED UNITIZED CARTRIDGE SEAL INSTALLED AS A SERVICE REPAIR. 1. Raise vehicle, refer to Workshop Manual (WSM), Section 100-02. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-19-3 > Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking > Page 5335 NOTE IF SEAL IS OLD DESIGN RADIAL LIP SEAL STYLE, (SEE FIGURES 1 AND 2 TO IDENTIFY RADIAL LIP SEAL) THERE IS NO INTERNAL GREASE PRESENT IN SEAL TO SEPARATE. THIS TSB DOES NOT APPLY. REFER TO WORKSHOP MANUAL DIAGNOSTIC. 2. Check axle half shaft seal to ensure that it is unitized cartridge design. 3. Clean axle housing around the seal area using Motorcraft® Metal Brake Parts Cleaner or equivalent cleaner. Wipe lube or oil with rag and let the housing dry. 4. Add 0.5 to 1 ounce (14.8 to 29.6 ml) Rotunda Dye-Lite® Leak Detection Dye for Gasoline Engine Oil 164-R3700, also contained in 164-R0756 to the axle following the appropriate Workshop Manual. NOTE ADDING THE DYE ON SOME VEHICLES WILL REQUIRE THE REAR WHEEL ABS SPEED SENSOR TO BE REMOVED. REFER TO THE APPROPRIATE WORKSHOP MANUAL DRAIN AND FILL PROCEDURE. 5. Road test vehicle a minimum distance 15 miles (24 km) at a minimum speed of 25 MPH (40 Km/h). NOTE A BRIGHT ORANGE AREA WILL IDENTIFY AXLE LUBE LEAK. FOR EXTREMELY SMALL OIL SEPARATION, ADDITIONAL AXLE OPERATION TIME MAY BE REQUIRED FOR THE LEAK TO APPEAR. 6. Raise vehicle to check for signs of leak. a. Use Rotunda 12V Master UV Leak Detector Kit 164-R0756 or equivalent to look for signs of leak. 7. If there is not a verifiable lube leak, clean axle near seal area and return the vehicle to the customer. NOTE IF THERE IS NO SIGNS OF LUBE LEAK, THIS MEANS THAT THE SUBSTANCE WHICH WAS PRESENT PRIOR TO THE PROCEDURE WAS OIL WHICH HAD SEPARATED FROM THE GREASE INTERNAL TO THE SEAL. THIS OIL IS A PRE-LUBE, AND IS NOT NECESSARY ONCE THE AXLE SEAL IS BROKEN IN. ONCE THE OIL SEPARATION HAS OCCURRED, THERE SHOULD BE NO Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-19-3 > Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking > Page 5336 FURTHER OIL SEPARATION FROM THE SEAL. REMOVING THE SEAL AND INSTALLING A NEW SEAL MIGHT CREATE A SITUATION WHERE THE OIL WILL SEPARATE, RESULTING IN THE SAME CONCERN. 8. If there is a verifiable axle lube leak, replace seal following the Workshop Manual (WSM), Section 205, or look at instruction sheet included in Axle Shaft Seal Kit. Parts Block 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 081903A 2003-2008 Expedition, 0.9 Hr. Navigator: INSPECT Axle Seal Leaks. Includes Time to Add Oil Dye and Road Test. This Labor Operation Can Be Claimed With Any Of The Labor Operations In This Article. (Do Not Use With 4139A, 4139A2) 081903A 2002-2008 Explorer, 0.7 Hr. Mountaineer, 2007-2008 Explorer Sport Trac, 2002-2005 Aviator: INSPECT Axle Seal Leaks. Includes Time to Add Oil Dye and Road Test. This Labor Operation Can Be Claimed With Any Of The Labor Operations In This Article. (Do Not Use With 4139A, 4139A2) 081903B 2003-2008 Expedition 1.3 Hrs. Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A, 4139A2) 081903C 2003-2008 Expedition 2.2 Hrs. Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A, 4139A2) 081903D 2003-2008 Expedition, 0.7 Hr. Navigator: Replace Rear Axle Stub Shaft Seal. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-19-3 > Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking > Page 5337 Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A, B, Or C (Do Not Use With 4139A, 4139A2) 081903D 2006-2008 Explorer, 1.1 Hrs. Mountaineer, 2007-2008 Explorer Sport Trac :Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) 081903D 2002-2005 Explorer, 0.9 Hr. Mountaineer:Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) 081903D 2003-2005 Aviator:Replace 0.8 Hr. Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) 081903E 2003-2008 Expedition, 1.2 Hrs. Navigator: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A, B, Or C (Do Not Use With 4139A, 4139A2) 081903E 2006-2008 Explorer, 2.1 Hrs. Mountaineer, 2007-2008 Explorer Sport Trac Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) 081903E 2002-2005 Explorer, 1.5 Hrs. Mountaineer: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A (Do Not Use With Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-19-3 > Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking > Page 5338 4139A, 4139A2) 081903E 2003-2005 Aviator: 1.6 Hrs. Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) DEALER CODING CONDITION BASIC PART NO. CODE 4A109 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-19-6 > Sep > 08 > Drivetrain - Rear Axle Squealing Noise Seals and Gaskets: All Technical Service Bulletins Drivetrain - Rear Axle Squealing Noise TSB 08-19-6 09/29/08 HIGH PITCHED SQUEAL NOISE FROM THE REAR AXLE AREA - BUILT ON OR BEFORE 7/28/2008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer ISSUE Some 2006-2008 Explorer, Mountaineer and 2007-2008 Sport Trac vehicles built on or before 7/28/2008 may exhibit a high pitched squeal noise from the rear axle area while driving at low speeds. This may be caused by the rear outer axle halfshaft dust seals contacting the knuckle surface. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Position vehicle on a hoist and place it in neutral. 2. Remove the rear wheel and tire. For additional information, refer to Workshop Manual (WSM), Section 204-04. 3. Remove and discard the rear axle wheel end nut. To install, tighten to 203 lb-ft (275 N.m). (Figure 1) CAUTION DO NOT USE A HAMMER TO SEPARATE THE REAR AXLE HALFSHAFT ASSEMBLY FROM THE HUB. DAMAGE TO THE THREADS AND INTERNAL CONSTANT VELOCITY (CV) JOINT COMPONENTS MAY RESULT. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-19-6 > Sep > 08 > Drivetrain - Rear Axle Squealing Noise > Page 5343 4. Use the special tool, press the outboard constant velocity (CV) joint until it is loose in the hub. (Figure 2) 5. Use a brush and apply Motorcraft(R) Silicone Brake Caliper Grease and Dielectric Compound to lubricate the rear axle halfshaft dust seal. 6. Reverse steps 2 and 3 to install halfshaft, tire, and wheel. Parts Block 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 081906A 2006-2008 0.5 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Lubricate One Rear Constant Velocity Outboard Joint to Knuckle Dust Seal: 0.5 Hrs(Do Not Use With 4139A, 5968A) 081906B 2006-2008 0.9 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Lubricate Both Rear Constant Velocity Outboard Joint to Knuckle Dust Seal: 0.9 Hrs (Do Not Use With 4139A, 5968A) DEALER CODING CONDITION BASIC PART NO. CODE 1175 14 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 5344 Seals and Gaskets: By Symptom Technical Service Bulletin # 08-19-6 Date: 080929 Drivetrain - Rear Axle Squealing Noise TSB 08-19-6 09/29/08 HIGH PITCHED SQUEAL NOISE FROM THE REAR AXLE AREA - BUILT ON OR BEFORE 7/28/2008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer ISSUE Some 2006-2008 Explorer, Mountaineer and 2007-2008 Sport Trac vehicles built on or before 7/28/2008 may exhibit a high pitched squeal noise from the rear axle area while driving at low speeds. This may be caused by the rear outer axle halfshaft dust seals contacting the knuckle surface. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Position vehicle on a hoist and place it in neutral. 2. Remove the rear wheel and tire. For additional information, refer to Workshop Manual (WSM), Section 204-04. 3. Remove and discard the rear axle wheel end nut. To install, tighten to 203 lb-ft (275 N.m). (Figure 1) CAUTION DO NOT USE A HAMMER TO SEPARATE THE REAR AXLE HALFSHAFT ASSEMBLY FROM THE HUB. DAMAGE TO THE THREADS AND INTERNAL CONSTANT VELOCITY (CV) JOINT COMPONENTS MAY RESULT. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 5345 4. Use the special tool, press the outboard constant velocity (CV) joint until it is loose in the hub. (Figure 2) 5. Use a brush and apply Motorcraft(R) Silicone Brake Caliper Grease and Dielectric Compound to lubricate the rear axle halfshaft dust seal. 6. Reverse steps 2 and 3 to install halfshaft, tire, and wheel. Parts Block 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 081906A 2006-2008 0.5 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Lubricate One Rear Constant Velocity Outboard Joint to Knuckle Dust Seal: 0.5 Hrs(Do Not Use With 4139A, 5968A) 081906B 2006-2008 0.9 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Lubricate Both Rear Constant Velocity Outboard Joint to Knuckle Dust Seal: 0.9 Hrs (Do Not Use With 4139A, 5968A) DEALER CODING CONDITION BASIC PART NO. CODE 1175 14 Disclaimer Technical Service Bulletin # 08-19-3 Date: 080929 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 5346 Drivetrain - Rear Axle Seal(s) Leaking TSB 08-19-3 09/29/08 UNITIZED SEAL DIAGNOSIS - LEAK / GREASE OIL SEPARATION - AXLE BEARING SEAL 8.8 IFS, 8.8 IRS, AND 9.75 IRS AXLES FORD: 2002-2008 Explorer 2003-2008 Expedition 2006-2008 Explorer Sport Trac LINCOLN: 2003-2005 Aviator 2003-2008 Navigator MERCURY: 2002-2008 Mountaineer This article supersedes TSB 06-22-05 to update the model years, Part List and Service Procedure. ISSUE Some 2006-2008 Expedition, Navigator, Explorer, Explorer Sport Track, and Mountaineer vehicles equipped with rear axle unitized cartridge seal, 2007-2008 Expedition-Navigator AWD equipped with front and rear axle unitized cartridge seal. 2003-2005 Expedition-Navigator, 2002-2005, Explorer-Mountaineer, 2003-2005 Aviator equipped with unitized cartridge rear axle seal, may exhibit oil separation from the internal lube found in the unitized cartridge seal. This oil separation appears to be, and is often misdiagnosed, as an axle lube leak. The majority of the vehicles with this condition will be located in northern Canada and Alaska due to the extreme cold weather. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE DO NOT REPLACE THE UNITIZED CARTRIDGE SEAL UNTIL YOU COMPLETE THIS DIAGNOSTIC SERVICE PROCEDURE. FAILURE TO PROPERLY DIAGNOSE THE ISSUE MAY RESULT IN UNNECESSARILY REPLACING THE SEAL, RESULTING IN A REPEAT CONCERN. NOTE THIS DIAGNOSTIC PROCEDURE IS ONLY NECESSARY ON VEHICLES WITH THE NEW UNITIZED CARTRIDGE SEAL. THIS SEAL HAS BEEN USED IN PRODUCTION FROM 2006 MODEL YEAR TO PRESENT, HOWEVER, SOME VEHICLES BUILT PRIOR TO 2006 MODEL YEAR MAY HAVE THIS NEW UPDATED UNITIZED CARTRIDGE SEAL INSTALLED AS A SERVICE REPAIR. 1. Raise vehicle, refer to Workshop Manual (WSM), Section 100-02. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 5347 NOTE IF SEAL IS OLD DESIGN RADIAL LIP SEAL STYLE, (SEE FIGURES 1 AND 2 TO IDENTIFY RADIAL LIP SEAL) THERE IS NO INTERNAL GREASE PRESENT IN SEAL TO SEPARATE. THIS TSB DOES NOT APPLY. REFER TO WORKSHOP MANUAL DIAGNOSTIC. 2. Check axle half shaft seal to ensure that it is unitized cartridge design. 3. Clean axle housing around the seal area using Motorcraft® Metal Brake Parts Cleaner or equivalent cleaner. Wipe lube or oil with rag and let the housing dry. 4. Add 0.5 to 1 ounce (14.8 to 29.6 ml) Rotunda Dye-Lite® Leak Detection Dye for Gasoline Engine Oil 164-R3700, also contained in 164-R0756 to the axle following the appropriate Workshop Manual. NOTE ADDING THE DYE ON SOME VEHICLES WILL REQUIRE THE REAR WHEEL ABS SPEED SENSOR TO BE REMOVED. REFER TO THE APPROPRIATE WORKSHOP MANUAL DRAIN AND FILL PROCEDURE. 5. Road test vehicle a minimum distance 15 miles (24 km) at a minimum speed of 25 MPH (40 Km/h). NOTE A BRIGHT ORANGE AREA WILL IDENTIFY AXLE LUBE LEAK. FOR EXTREMELY SMALL OIL SEPARATION, ADDITIONAL AXLE OPERATION TIME MAY BE REQUIRED FOR THE LEAK TO APPEAR. 6. Raise vehicle to check for signs of leak. a. Use Rotunda 12V Master UV Leak Detector Kit 164-R0756 or equivalent to look for signs of leak. 7. If there is not a verifiable lube leak, clean axle near seal area and return the vehicle to the customer. NOTE IF THERE IS NO SIGNS OF LUBE LEAK, THIS MEANS THAT THE SUBSTANCE WHICH WAS PRESENT PRIOR TO THE PROCEDURE WAS OIL WHICH HAD SEPARATED FROM THE GREASE INTERNAL TO THE SEAL. THIS OIL IS A PRE-LUBE, AND IS NOT NECESSARY ONCE THE AXLE SEAL IS BROKEN IN. ONCE THE OIL SEPARATION HAS OCCURRED, THERE SHOULD BE NO Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 5348 FURTHER OIL SEPARATION FROM THE SEAL. REMOVING THE SEAL AND INSTALLING A NEW SEAL MIGHT CREATE A SITUATION WHERE THE OIL WILL SEPARATE, RESULTING IN THE SAME CONCERN. 8. If there is a verifiable axle lube leak, replace seal following the Workshop Manual (WSM), Section 205, or look at instruction sheet included in Axle Shaft Seal Kit. Parts Block 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 081903A 2003-2008 Expedition, 0.9 Hr. Navigator: INSPECT Axle Seal Leaks. Includes Time to Add Oil Dye and Road Test. This Labor Operation Can Be Claimed With Any Of The Labor Operations In This Article. (Do Not Use With 4139A, 4139A2) 081903A 2002-2008 Explorer, 0.7 Hr. Mountaineer, 2007-2008 Explorer Sport Trac, 2002-2005 Aviator: INSPECT Axle Seal Leaks. Includes Time to Add Oil Dye and Road Test. This Labor Operation Can Be Claimed With Any Of The Labor Operations In This Article. (Do Not Use With 4139A, 4139A2) 081903B 2003-2008 Expedition 1.3 Hrs. Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A, 4139A2) 081903C 2003-2008 Expedition 2.2 Hrs. Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A, 4139A2) 081903D 2003-2008 Expedition, 0.7 Hr. Navigator: Replace Rear Axle Stub Shaft Seal. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 5349 Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A, B, Or C (Do Not Use With 4139A, 4139A2) 081903D 2006-2008 Explorer, 1.1 Hrs. Mountaineer, 2007-2008 Explorer Sport Trac :Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) 081903D 2002-2005 Explorer, 0.9 Hr. Mountaineer:Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) 081903D 2003-2005 Aviator:Replace 0.8 Hr. Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) 081903E 2003-2008 Expedition, 1.2 Hrs. Navigator: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A, B, Or C (Do Not Use With 4139A, 4139A2) 081903E 2006-2008 Explorer, 2.1 Hrs. Mountaineer, 2007-2008 Explorer Sport Trac Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) 081903E 2002-2005 Explorer, 1.5 Hrs. Mountaineer: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A (Do Not Use With Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 5350 4139A, 4139A2) 081903E 2003-2005 Aviator: 1.6 Hrs. Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) DEALER CODING CONDITION BASIC PART NO. CODE 4A109 42 Disclaimer Technical Service Bulletin # 08-19-3 Date: 080929 Drivetrain - Rear Axle Seal(s) Leaking TSB 08-19-3 09/29/08 UNITIZED SEAL DIAGNOSIS - LEAK / GREASE OIL SEPARATION - AXLE BEARING SEAL 8.8 IFS, 8.8 IRS, AND 9.75 IRS AXLES FORD: 2002-2008 Explorer 2003-2008 Expedition 2006-2008 Explorer Sport Trac LINCOLN: 2003-2005 Aviator 2003-2008 Navigator MERCURY: 2002-2008 Mountaineer This article supersedes TSB 06-22-05 to update the model years, Part List and Service Procedure. ISSUE Some 2006-2008 Expedition, Navigator, Explorer, Explorer Sport Track, and Mountaineer vehicles equipped with rear axle unitized cartridge seal, 2007-2008 Expedition-Navigator AWD equipped with front and rear axle unitized cartridge seal. 2003-2005 Expedition-Navigator, 2002-2005, Explorer-Mountaineer, 2003-2005 Aviator equipped with unitized cartridge rear axle seal, may exhibit oil separation from the internal lube found in the unitized cartridge seal. This oil separation appears to be, and is often misdiagnosed, as an axle lube leak. The majority of the vehicles with this condition will be located in northern Canada and Alaska due to the extreme cold weather. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE DO NOT REPLACE THE UNITIZED CARTRIDGE SEAL UNTIL YOU COMPLETE THIS DIAGNOSTIC SERVICE PROCEDURE. FAILURE TO PROPERLY DIAGNOSE THE ISSUE MAY RESULT IN UNNECESSARILY REPLACING THE SEAL, RESULTING IN A REPEAT CONCERN. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 5351 NOTE THIS DIAGNOSTIC PROCEDURE IS ONLY NECESSARY ON VEHICLES WITH THE NEW UNITIZED CARTRIDGE SEAL. THIS SEAL HAS BEEN USED IN PRODUCTION FROM 2006 MODEL YEAR TO PRESENT, HOWEVER, SOME VEHICLES BUILT PRIOR TO 2006 MODEL YEAR MAY HAVE THIS NEW UPDATED UNITIZED CARTRIDGE SEAL INSTALLED AS A SERVICE REPAIR. 1. Raise vehicle, refer to Workshop Manual (WSM), Section 100-02. NOTE IF SEAL IS OLD DESIGN RADIAL LIP SEAL STYLE, (SEE FIGURES 1 AND 2 TO IDENTIFY RADIAL LIP SEAL) THERE IS NO INTERNAL GREASE PRESENT IN SEAL TO SEPARATE. THIS TSB DOES NOT APPLY. REFER TO WORKSHOP MANUAL DIAGNOSTIC. 2. Check axle half shaft seal to ensure that it is unitized cartridge design. 3. Clean axle housing around the seal area using Motorcraft® Metal Brake Parts Cleaner or equivalent cleaner. Wipe lube or oil with rag and let the housing dry. 4. Add 0.5 to 1 ounce (14.8 to 29.6 ml) Rotunda Dye-Lite® Leak Detection Dye for Gasoline Engine Oil 164-R3700, also contained in 164-R0756 to the axle following the appropriate Workshop Manual. NOTE ADDING THE DYE ON SOME VEHICLES WILL REQUIRE THE REAR WHEEL ABS SPEED SENSOR TO BE REMOVED. REFER TO THE APPROPRIATE WORKSHOP MANUAL DRAIN AND FILL PROCEDURE. 5. Road test vehicle a minimum distance 15 miles (24 km) at a minimum speed of 25 MPH (40 Km/h). NOTE A BRIGHT ORANGE AREA WILL IDENTIFY AXLE LUBE LEAK. FOR EXTREMELY SMALL OIL SEPARATION, ADDITIONAL AXLE OPERATION TIME MAY BE REQUIRED FOR THE LEAK TO APPEAR. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 5352 6. Raise vehicle to check for signs of leak. a. Use Rotunda 12V Master UV Leak Detector Kit 164-R0756 or equivalent to look for signs of leak. 7. If there is not a verifiable lube leak, clean axle near seal area and return the vehicle to the customer. NOTE IF THERE IS NO SIGNS OF LUBE LEAK, THIS MEANS THAT THE SUBSTANCE WHICH WAS PRESENT PRIOR TO THE PROCEDURE WAS OIL WHICH HAD SEPARATED FROM THE GREASE INTERNAL TO THE SEAL. THIS OIL IS A PRE-LUBE, AND IS NOT NECESSARY ONCE THE AXLE SEAL IS BROKEN IN. ONCE THE OIL SEPARATION HAS OCCURRED, THERE SHOULD BE NO FURTHER OIL SEPARATION FROM THE SEAL. REMOVING THE SEAL AND INSTALLING A NEW SEAL MIGHT CREATE A SITUATION WHERE THE OIL WILL SEPARATE, RESULTING IN THE SAME CONCERN. 8. If there is a verifiable axle lube leak, replace seal following the Workshop Manual (WSM), Section 205, or look at instruction sheet included in Axle Shaft Seal Kit. Parts Block 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 081903A 2003-2008 Expedition, 0.9 Hr. Navigator: INSPECT Axle Seal Leaks. Includes Time to Add Oil Dye and Road Test. This Labor Operation Can Be Claimed With Any Of The Labor Operations In This Article. (Do Not Use With 4139A, 4139A2) 081903A 2002-2008 Explorer, 0.7 Hr. Mountaineer, 2007-2008 Explorer Sport Trac, 2002-2005 Aviator: INSPECT Axle Seal Leaks. Includes Time to Add Oil Dye and Road Test. This Labor Operation Can Be Claimed With Any Of The Labor Operations In This Article. (Do Not Use With 4139A, 4139A2) 081903B 2003-2008 Expedition 1.3 Hrs. Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A, 4139A2) 081903C 2003-2008 Expedition 2.2 Hrs. Navigator: Replace Front Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 5353 Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A, 4139A2) 081903D 2003-2008 Expedition, 0.7 Hr. Navigator: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A, B, Or C (Do Not Use With 4139A, 4139A2) 081903D 2006-2008 Explorer, 1.1 Hrs. Mountaineer, 2007-2008 Explorer Sport Trac :Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) 081903D 2002-2005 Explorer, 0.9 Hr. Mountaineer:Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) 081903D 2003-2005 Aviator:Replace 0.8 Hr. Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) 081903E 2003-2008 Expedition, 1.2 Hrs. Navigator: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A, B, Or C (Do Not Use With 4139A, 4139A2) 081903E 2006-2008 Explorer, 2.1 Hrs. Mountaineer, 2007-2008 Explorer Sport Trac Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 5354 Claimed With A (Do Not Use With 4139A, 4139A2) 081903E 2002-2005 Explorer, 1.5 Hrs. Mountaineer: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) 081903E 2003-2005 Aviator: 1.6 Hrs. Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2) DEALER CODING CONDITION BASIC PART NO. CODE 4A109 42 Disclaimer Technical Service Bulletin # 08-19-6 Date: 080929 Drivetrain - Rear Axle Squealing Noise TSB 08-19-6 09/29/08 HIGH PITCHED SQUEAL NOISE FROM THE REAR AXLE AREA - BUILT ON OR BEFORE 7/28/2008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer ISSUE Some 2006-2008 Explorer, Mountaineer and 2007-2008 Sport Trac vehicles built on or before 7/28/2008 may exhibit a high pitched squeal noise from the rear axle area while driving at low speeds. This may be caused by the rear outer axle halfshaft dust seals contacting the knuckle surface. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Position vehicle on a hoist and place it in neutral. 2. Remove the rear wheel and tire. For additional information, refer to Workshop Manual (WSM), Section 204-04. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 5355 3. Remove and discard the rear axle wheel end nut. To install, tighten to 203 lb-ft (275 N.m). (Figure 1) CAUTION DO NOT USE A HAMMER TO SEPARATE THE REAR AXLE HALFSHAFT ASSEMBLY FROM THE HUB. DAMAGE TO THE THREADS AND INTERNAL CONSTANT VELOCITY (CV) JOINT COMPONENTS MAY RESULT. 4. Use the special tool, press the outboard constant velocity (CV) joint until it is loose in the hub. (Figure 2) 5. Use a brush and apply Motorcraft(R) Silicone Brake Caliper Grease and Dielectric Compound to lubricate the rear axle halfshaft dust seal. 6. Reverse steps 2 and 3 to install halfshaft, tire, and wheel. Parts Block 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 081906A 2006-2008 0.5 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Lubricate One Rear Constant Velocity Outboard Joint to Knuckle Dust Seal: 0.5 Hrs(Do Not Use With 4139A, 5968A) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 5356 081906B 2006-2008 0.9 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Lubricate Both Rear Constant Velocity Outboard Joint to Knuckle Dust Seal: 0.9 Hrs (Do Not Use With 4139A, 5968A) DEALER CODING CONDITION BASIC PART NO. CODE 1175 14 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Wheel Bearing and Wheel Hub Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number or an equivalent part must be installed, if installation is necessary. Do not use a part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose can occur. Remove the bolts and position the caliper, pads and anchor plate assembly aside. ^ Discard the bolts. ^ Support the caliper and anchor plate assembly using mechanic's wire. ^ To install, tighten to 165 Nm (122 ft. lbs.) 3. Remove the brake disc. 4. CAUTION: Inspect and if necessary, clean area around wheel speed sensor before removing it from the wheel bearing and hub. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5361 Remove the wheel speed sensor bolt and disconnect the wheel speed sensor from the wheel bearing and hub assembly. ^ To install, tighten to 18 Nm (13 ft. lbs.) 5. Remove the 3 bolts and the wheel bearing and hub assembly. ^ Discard the bolts. ^ To install, tighten to 122 Nm (90 ft. lbs.) 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5362 Wheel Bearing: Service and Repair Rear Wheel Bearing and Wheel Hub Special Tool(s) Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Remove the wheel knuckle. 2. Remove the 3 brake disc shield bolts. ^ To install, tighten to 8 Nm (71 inch lbs.) 3. Using the special tool and a suitable press, remove the wheel hub. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5363 4. Remove the snap ring. 5. Using a suitable press and adapters, remove the wheel bearing. 6. To install, reverse the removal procedure. 7. Install the wheel knuckle. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Testing and Inspection > Driveline System Wheel Hub: Testing and Inspection Driveline System Inspection and Verification Certain axle and driveline symptoms are also common to the engine, transmission, wheel bearings, tires and other parts of the vehicle. For this reason, be sure that the cause of the concern is in the axle before disassembling, adjusting or repairing the axle. Refer to Vehicle/Testing and Inspection. Certain driveshaft vibration symptoms are common to the front engine accessory drive (FEAD), the engine, transmission or tires. Be sure the cause of the concern is the driveshaft before repairing or installing a new driveshaft. Refer to Vehicle/Testing and Inspection. Noise Acceptability A gear-driven unit will produce a certain amount of noise. Some noise is acceptable and audible at certain speeds or under various driving conditions, such as a newly paved blacktop road. Slight noise is not detrimental to the operation of the axle and is considered normal. Universal Joint (U-Joint) Inspection Place the vehicle on a frame hoist and rotate the driveshaft by hand. Check for rough operation or seized U-joints. Install a new U-joint if it shows signs of seizure, excessive wear or incorrect seating. Analysis of Leakage Clean up the leaking area enough to identify the exact source. An axle leak can be caused by: ^ Axle lubricant level is too high ^ Worn or damaged axle shaft seals or differential seals ^ Differential housing is cracked ^ Flange yoke seal is worn or damaged ^ Pinion flange is scored or damaged ^ Axle cover is not sealed ^ Vent is plugged Repair the axle as necessary. Make sure the axle lubricant is at the correct level. Axle Vent NOTE: If a plugged vent cannot be cleared, install a new vent. NOTE: If the vent is removed from the housing for any reason, a new vent must be installed. A plugged vent will cause excessive seal lip wear due to internal pressure buildup. If a leak occurs, check the vent. Make sure the vent hose is not kinked. Remove the hose from the vent nipple and clear the hose of any foreign material. While the hose is removed, pass a length of mechanic's wire or a small diameter Allen wrench in and out of the vent to clean it. Connect the hose when done. Flange Yoke Seal Leaks at the axle drive pinion seal originate for these reasons: ^ The seal is not correctly installed ^ A poor quality seal journal surface Any damage to the seal bore (dings, dents, gouges or other imperfections) will distort the seal casing and allow leakage past the outer edge of the axle drive pinion seal. The axle drive pinion seal can be torn, cut or gouged if it is not installed carefully. The spring that holds the axle drive pinion seal against the pinion flange can be knocked out, which can allow leakage past the lip. The rubber lips can occasionally become hard (like plastic) with cracks at the oil lip contact point. The contact point on the pinion flange may blacken, indicating excessive heat. Marks, nicks, gouges or rough surface texture on the seal journal of the pinion flange will also cause leaks. A new pinion flange must be installed if any of these conditions exist. Metal chips or sand trapped at the sealing lip can also cause oil leaks. This can cause a wear groove on the pinion flange and heavy pinion seal wear. When a seal leak occurs, install a new seal and check the vent and the vent hose to make sure they are clean and free of foreign material. Analysis of Vibration WARNING: An all-wheel drive (AWD) vehicle will always have all wheels (on both axles) driving. If only one wheel/axle is raised off the floor and the axle is driven by the engine, the wheel/axle on the floor could drive the vehicle off the stand or jack. Be sure all wheels are off the floor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Testing and Inspection > Driveline System > Page 5368 Few vibration conditions are caused by the front or rear axle. For a vibration concern, follow the diagnosis procedure in Vehicle/Testing and Inspection unless there is a good reason to suspect the axle. Tires WARNING: Do not balance the wheels and tires while they are mounted on the vehicle. Possible tire disintegration or differential failure could result, causing personal injury or extensive component damage. Use an off-vehicle wheel and tire balancer only. Most vibration is caused by tires, driveline angle or driveline imbalance. Vibration is a concern with modern, high-mileage tires if they are not "true" both radially and laterally. They are more susceptible to vibration around the limits of radial and lateral runout of the tire and wheel assembly. They also require more accurate balancing. Wheel and tire runout checks, truing and balancing are normally done before axle inspection. Driveline Imbalance Driveline imbalance can be caused by excessive looseness in the driveshaft, damaged driveshaft tubing, looseness or high runout at the driveshaft attachments (axle and transfer case flanges). Excessive looseness in the driveshaft can be caused by CV joint or universal joint wear, as well as loose fitting slip-yoke splines. Inspect and install new driveshaft components as necessary. Driveline Angle Driveline Angle Driveline angularity is the angular relationship between the engine crankshaft, the driveshaft and the rear axle pinion. Some of the factors determining driveline angularity include ride height, rear spring and engine mounts. An incorrect driveline (pinion) angle can often be detected by examining the driving condition in which the vibration occurs. ^ A vibration during coastdown, from 72 to 56 km/h (45 to 35 mph), is often caused by an excessive U-joint angle at the axle (pinion nose downward). ^ A vibration during acceleration, from 56 to 72 km/h (35 to 45 mph), may indicate an excessive U-joint angle at the axle (pinion nose upward). When these conditions exist, check the driveline angles. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Testing and Inspection > Driveline System > Page 5369 Universal Joint (U-Joint) Wear Place the vehicle on a frame hoist and rotate the driveshaft by hand. Check for rough operation or seized U-joints. Install a new U-joint if it shows signs of seizure, excessive wear or incorrect seating. Wheel Hub Bolt Circle Runout NOTE: The brake discs must be removed to carry out all runout measurements. 1. Position the special tool on the wheel hub bolt, as close to the hub face as possible. Zero the indicator to allow the pointer to deflect either way. 2. Rotate the hub until the next bolt is contacted. Record the measurement and continue until each bolt is checked. The difference between the maximum and minimum contact readings will be the total wheel hub bolt circle runout. The runout must not exceed 0.38 mm (0.015 inch). Pilot Runout 1. Position the special tools on the pilot, as close to the hub as possible. Zero the indicator to allow the pointer to deflect either way. 2. Rotate the hub one full turn and note the maximum and minimum readings. The difference between the maximum and minimum readings will be the total pilot runout. Pilot runout must not exceed 0.15 mm (0.006 inch). Wheel Hub Runout 1. Position the special tool on the wheel hub, as close to the outer edge as possible. Zero the indicator to allow the pointer to deflect either way. 2. Rotate the hub one full turn and note the maximum and minimum readings. The difference between the maximum and minimum readings will be the total wheel hub runout. The runout must not exceed 0.127 mm (0.005 inch). Drive Pinion Stem and Pinion Flange Check the pinion flange runout when all other checks have failed to show the cause of the vibration. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Testing and Inspection > Driveline System > Page 5370 One cause of excessive pinion flange runout is incorrect installation of the axle drive pinion seal. Check to determine if the spring on the seal lip has been dislodged. Halfshafts NOTE: Constant velocity (CV) joints must not be installed unless disassembly and inspection reveals unusual wear. NOTE: While inspecting the boots, watch for indentations ("dimples") in the boot convolutions. Indentations must be removed. ^ Inspect the boots for evidence of cracks, tears or splits. ^ Inspect the underbody for any indication of grease splatter near the boots outboard and inboard locations. This is an indication of boot/clamp damage. Axle Noise NOTE: Before disassembling the axle to diagnose and correct gear noise, eliminate the tires, exhaust, trim items, roof racks and wheel bearings as possible causes. Follow the diagnostic procedures in Vehicle/Testing and Inspection. The noises described as follows usually have specific causes that can be diagnosed by observation as the unit is disassembled. The initial clues are the type of noise heard during the road test. Gear Howl and Whine Howling or whining of the ring gear and pinion is due to an incorrect gear pattern, gear damage or incorrect bearing preload. Bearing Whine Bearing whine is a high-pitched sound similar to a whistle. It is usually caused by worn/damaged pinion bearings, which are operating at driveshaft speed. Bearing noise occurs at all driving speeds. This distinguishes it from gear whine which usually comes and goes as speed changes. As noted, pinion bearings make a high-pitched, whistling noise, usually at all speeds. If however there is only one pinion bearing that is worn/damaged, the noise may vary in different driving phases. New pinion bearings must not be installed unless they are scored or damaged, or there is a specific pinion bearing noise. A worn/damaged bearing will normally be obvious at disassembly. Examine the large end of the rollers for wear. If the pinion bearings original blend radius has worn to a sharp edge, a new pinion bearing must be installed. A wheel bearing noise can be mistaken for a pinion bearing noise. On rear wheel drive (RWD) vehicles, check the wheel bearing for a spalled cup and spalled/damaged rollers. Install a new wheel bearing if any of these concerns are detected. On four wheel drive (4WD) vehicles, check the wheel bearing for rotating smoothness and end play. Chuckle Chuckle that occurs on the coast driving phase is usually caused by excessive clearance between the differential gear hub and the differential case bore. Damage to a gear tooth on the coast side can cause a noise identical to a chuckle. A very small tooth nick or ridge on the edge of a tooth can cause the noise. Clean the gear tooth nick or ridge with a small grinding wheel. If the damaged area is larger than 3.2 mm (1/8 inch), install a new gearset. To check the ring gear and pinion, remove as much lubricant as possible from the gears with clean solvent. Wipe the gears dry or blow them dry with compressed air. Look for scored or damaged teeth. Also look for cracks or other damage. If either gear is scored or damaged badly, a new ring gear and pinion must be installed. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Testing and Inspection > Driveline System > Page 5371 If metal has broken loose, the axle housing must be cleaned to remove particles that will cause damage. At this time, any other damaged parts in the axle housing must also be installed new. Knock Knock, which can occur in all driving phases, has several causes including damaged teeth or gearset. 1. NOTE: Measure the end play with a Dial Indicator with Bracketry and not by feel. Knock is also caused by excessive end play in the axle shafts. Up to 0.762 mm (0.030 inch) is allowed in semi-float axles. The frequency of the knock will be less because the axle shaft speed is slower than the driveshaft. Clunk Clunk is a metallic noise heard when the automatic transmission is engaged in REVERSE or DRIVE. The noise can also occur when throttle is applied or released. It is caused by backlash somewhere in the driveline or loose suspension components; it is felt or heard in the axle. Additionally, clunk may be heard upon initial drive-away. This occurs as engine torque shifts vehicle weight, forcing changes in driveline angles which prevent the driveshaft slip-yoke from sliding on the output shaft. To correct this condition, lubricate the slip-yoke splines. Bearing Rumble Bearing rumble sounds like marbles being tumbled. This condition is usually caused by a worn/damaged wheel bearing. The lower pitch is because the wheel bearing turns at only about 1/3 of the driveshaft speed. Wheel bearing noise also may be high-pitched, similar to gear noise, but will be evident in all 4 driving modes. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Testing and Inspection > Driveline System > Page 5372 Wheel Hub: Testing and Inspection Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear Inspection and Verification Special Tool(s) Material The technician should have a thorough knowledge of driveline system operation and accepted general driveline guidelines to detect any problems. A gear driven unit will produce a certain amount of noise. Some noise is acceptable and audible at certain speeds or under various driving conditions. Certain conditions, such as road conditions and weather, will amplify normal vehicle noise. Certain rear axle and driveline concern symptoms are also common to the engine, transmission, rear wheel bearings and tire. For this reason, be sure the cause of the concern is in the axle before repairing or installing any axle components. This is a guide to diagnose a driveline concern: ^ Verify and document the customer concern. ^ Carry out a preliminary investigation. ^ Road test the vehicle. ^ Find the cause of the problem. ^ Inspect the components. 1. Verify and document the customer concern. 1 When was it first noticed? 2 Did it appear suddenly or gradually? 3 Did anything unusual occur that would coincide with it or precede it? 4 Has the driveline system been repaired before or new components installed? ^ Check the vehicle service record. Note any repairs other than driveline, such as brakes or suspension. 5 Are there any special conditions that will affect the concern or will alter the concern? For example, ^ road speed. ^ type of road. ^ drive mode. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Testing and Inspection > Driveline System > Page 5373 ^ temperature. ^ vehicle loaded or unloaded. 6 Is the condition constant or intermittent? Can the concern be duplicated at any time? 7 Check for TSBs. 2. NOTE: If the inspection reveals an obvious concern, repair the vehicle. Do a preliminary investigation. Visually inspect for obvious signs of damage. 1 Inspect the driveshaft: ^ for build up of any foreign material. ^ for damage, such as a bent tube or missing weights. ^ U-joints, CV joints or flex couplers for wear or damage. 2 Inspect the axle: ^ for signs of leakage at the drain or fill plug, differential seal, vent or halfshaft seals. a plugged vent or vent tube will cause a leak. ^ for damage, such as cracks, bent halfshafts or dented rear cover. ^ for missing fasteners. 3 Inspect other suspect components/systems: ^ inspect the suspension for broken springs, damaged shock absorbers and worn suspension bushings. ^ inspect the rear brake components - lines, cables and calipers. ^ inspect the tires; are they in good condition and do they match? 3. NOTE: A road test is necessary for any customer concern of noise or vibration. Road test the vehicle. 1 During the road test, use these driving methods to diagnose the problem. Is the concern most noticeable: ^ from a stop? ^ on shifts from REVERSE to DRIVE? ^ on turns? sweeping type turn. - tight turn (to the stop). ^ in DRIVE? accelerating the vehicle, definite throttle depression, applying engine torque. ^ in CRUISE? - maintaining a constant speed with the throttle applied. ^ in COAST? decelerating with the throttle closed. 2 Record when the concern occurs. Write down the kph (mph) range at which the noise/vibration occurs. 4. Find the cause of the problem. 1 Compare the inspection and road test results with the chart. 2 Use this diagnostic routine chart to identify the probable cause and know what corrective actions should be taken to repair the component/vehicle and to prevent a reoccurrence. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Testing and Inspection > Driveline System > Page 5374 Diagnostic Routine Chart 5. NOTE: If the conclusion of the road test points to an axle assembly section (ring and pinion or differential case) concern, carry out a visual inspection of the rear axle. Inspect the axle components. 1 Remove the axle assembly. 2 Remove the differential housing cover. Drain the axle lubricant through a white cloth. Check the fluid for: ^ any foreign material. ^ metal particles. ^ burnt odor. 3 NOTE: When inspecting the axle, do not clean the components immediately. Cleaning may remove diagnostic evidence. Inspect the axle components. ^ Look for: loose fasteners. - notches or visible steps or grooves created by wear. - pitting or cracking along gear contact lines. - scuffing or deformations. - discolorations. - nicks or ridges on gear teeth. ^ Clean the axle components for inspection. Remove as much lubricant as possible with clean solvent. Wipe the components or blow them dry with compressed air. ^ Re-inspect for: Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Testing and Inspection > Driveline System > Page 5375 - loose fasteners. - notches or visible steps or grooves created by wear. - pitting or cracking along gear contact lines. - scuffing or deformations. - discolorations. - nicks or ridges on gear teeth. ^ Check backlash and carry out a ring and pinion pattern test. See: Differential Assembly/Testing and Inspection/Component Tests and General Diagnostics/Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear/Checking Tooth Contact Pattern and Condition of The Ring and Pinion Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Service and Repair > Front Wheel Hub: Service and Repair Front Wheel Bearing and Wheel Hub Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number or an equivalent part must be installed, if installation is necessary. Do not use a part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose can occur. Remove the bolts and position the caliper, pads and anchor plate assembly aside. ^ Discard the bolts. ^ Support the caliper and anchor plate assembly using mechanic's wire. ^ To install, tighten to 165 Nm (122 ft. lbs.) 3. Remove the brake disc. 4. CAUTION: Inspect and if necessary, clean area around wheel speed sensor before removing it from the wheel bearing and hub. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Service and Repair > Front > Page 5378 Remove the wheel speed sensor bolt and disconnect the wheel speed sensor from the wheel bearing and hub assembly. ^ To install, tighten to 18 Nm (13 ft. lbs.) 5. Remove the 3 bolts and the wheel bearing and hub assembly. ^ Discard the bolts. ^ To install, tighten to 122 Nm (90 ft. lbs.) 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Service and Repair > Front > Page 5379 Wheel Hub: Service and Repair Rear Wheel Bearing and Wheel Hub Special Tool(s) Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Remove the wheel knuckle. 2. Remove the 3 brake disc shield bolts. ^ To install, tighten to 8 Nm (71 inch lbs.) 3. Using the special tool and a suitable press, remove the wheel hub. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Service and Repair > Front > Page 5380 4. Remove the snap ring. 5. Using a suitable press and adapters, remove the wheel bearing. 6. To install, reverse the removal procedure. 7. Install the wheel knuckle. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair Center Support: Service and Repair Driveshaft Center Bearing Disassembly NOTE: The driveshaft center bearing on driveshafts with constant velocity (CV) joint flanges are not serviced. If the driveshaft center bearing is worn or damaged, install a new driveshaft. 1. Remove the driveshaft. 2. CAUTION: Do not clamp the driveshaft tube in a vise. Denting or localized fracturing may result causing driveshaft failure during vehicle operation. Position the center universal joint yoke ears in a vise so that the C-washer is pointing up and the front section is free to move. 3. Loosen the bolt inside the center cardan joint enough to allow the C-washer to fall from under the bolt head. ^ To install, tighten to 37 Nm (27 ft. lbs.) 4. NOTE: Index-mark the front and rear driveshaft sections. NOTE: The rear section has a master splined shaft and yoke. NOTE: The bolt head will fit through the internal spline of the center cardan. Using a rubber mallet, separate the driveshaft sections. 5. Using a suitable puller, remove the driveshaft center bearing from the rear section. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Page 5385 6. NOTE: Install the new center bearing with the 3 bend tabs and dust seal lip facing the front of the vehicle. To install, reverse the removal process. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Rear, One-Piece, Rear Wheel Drive (RWD) Drive/Propeller Shaft: Service and Repair Driveshaft - Rear, One-Piece, Rear Wheel Drive (RWD) Driveshaft - Rear, One-Piece, Rear Wheel Drive (RWD) Material Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. NOTE: Make sure the index marks on the extension housing and driveshaft are aligned before separation. NOTE: After removing the driveshaft, place an index mark on the transmission output shaft that matches the transmission extension housing mark. Index-mark the driveshaft and the extension housing to maintain driveshaft balance. 3. Index-mark the driveshaft flange to the pinion flange to maintain driveshaft balance. 4. Remove and discard the 4 driveshaft flange bolts. ^ To install, tighten to 112 Nm (83 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Rear, One-Piece, Rear Wheel Drive (RWD) > Page 5390 5. NOTE: The driveshaft flange yoke fits tightly on the pinion flange pilot. Never hammer on the driveshaft, or any of its components, to disconnect the driveshaft flange from the pinion flange. Using a suitable tool, pry only in the area shown to separate the driveshaft flange yoke from the pinion flange. 6. CAUTION: The driveshaft flanges fit tightly on the pinion flange pilot. To make sure that the driveshaft flange seats squarely on the pinion flange, tighten the driveshaft flange bolts evenly in a star pattern. CAUTION: If new driveshaft flange bolts are not available, coat the threads of the original driveshaft flange bolts with Threadlock and sealer. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Rear, One-Piece, Rear Wheel Drive (RWD) > Page 5391 Drive/Propeller Shaft: Service and Repair Driveshaft - Rear, Two-Piece, Rear Wheel Drive (RWD) Driveshaft - Rear, Two-Piece, Rear Wheel Drive (RWD) All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the nuts from the driveshaft center bearing bracket. ^ To install, tighten to 55 Nm (41 ft. lbs.) 3. Index-mark the rear universal joint flange to the differential pinion flange. 4. NOTE: After removing the driveshaft, without rotating the driveshaft, place an index mark on the transmission output shaft that matches the transmission extension housing mark. Index-mark the driveshaft and the extension housing. 4.6L engine 5. Index-mark the front universal joint flange to the transmission output flange. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Rear, One-Piece, Rear Wheel Drive (RWD) > Page 5392 6. Remove and discard the 4 driveshaft flange bolts from the transmission output shaft flange. ^ To install, tighten to 112 Nm (83 ft. lbs.) All vehicles 7. Remove and discard the 4 driveshaft flange bolts from the drive pinion flange. ^ To install, tighten to 112 Nm (83 ft. lbs.) 8. NOTE: Never hammer on the driveshaft, or any of its components, to disconnect the driveshaft flange from the differential pinion flange. Using a suitable tool, pry only in the area shown to separate the driveshaft flange and the differential pinion or transmission output flange. 9. Slide the driveshaft toward the rear of the vehicle, while maneuvering the front section over the top of the vehicle frame crossmember. 10. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Rear, One-Piece, Rear Wheel Drive (RWD) > Page 5393 Drive/Propeller Shaft: Service and Repair Driveshaft Slip Yoke Boot Driveshaft Slip Yoke Boot Special Tool(s) Material Removal 1. Remove the driveshaft. 2. Index-mark the driveshaft on both sides of the driveshaft slip yoke boot. 3. Remove and discard the driveshaft slip yoke boot clamps. 4. Separate the driveshaft. Remove the driveshaft slip yoke boot. Installation 1. NOTE: Grease both ends of the driveshaft. Position the driveshaft slip yoke boot and the driveshaft slip yoke boot clamps on one end of the driveshaft. 2. Align the index marks and connect the driveshaft. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft - Rear, One-Piece, Rear Wheel Drive (RWD) > Page 5394 3. Using the special tool, install the new driveshaft slip yoke boot. 4. Install the driveshaft. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft Universal Joint - Snap Ring Type Universal Joint: Service and Repair Driveshaft Universal Joint - Snap Ring Type Driveshaft Universal Joint - Snap Ring Type Special Tool(s) Disassembly and Assembly NOTE: The front driveshaft constant velocity (CV) joint is not repairable. 1. Remove the driveshaft. 2. Index-mark the components at the universal joints for reassembly. 3. Remove and discard the 4 snap rings. 4. Position the driveshaft in the special tool. Using the special tool, press out a bearing cup. 5. If necessary, use a pair of pliers to remove the bearing cup if it cannot be pressed all the way out. 6. Rotate the driveshaft and press on the spider to remove the remaining bearing cup. 7. Remove the driveshaft flange. 8. Position the driveshaft in the special tool. Using the special tool, press out the bearing cup. 9. If necessary, use a pair of pliers to remove the bearing cup if it cannot be pressed all the way out. 10. Rotate the driveshaft and press on the spider to remove the remaining bearing cup. 11. Remove the spider. 12. NOTE: Clean the bearing cup bores. NOTE: Check the universal joints for freedom of movement. If binding, strike the driveshaft flange with a brass or plastic hammer. Do not strike the universal joint. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft Universal Joint - Snap Ring Type > Page 5399 To assemble, reverse the disassembly procedure. ^ Use the yellow snap rings supplied in the kit to install the universal joint. If difficulty is encountered with the yellow snap rings, install the black snap rings, as required. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft Universal Joint - Snap Ring Type > Page 5400 Universal Joint: Service and Repair Driveshaft Universal Joint - Stake Type Driveshaft Universal Joint - Stake Type 1. The staked driveshaft universal joints are not serviced separately within the warranty period. Install a new driveshaft if worn or damaged. 2. Universal joint service kits with instructions are available through a Ford authorized dealer for a high mileage repair. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Flex plate bolts Stage 1: Tighten to .............................................................................................................................. ................................................ 13 Nm (10 ft. lbs.). Stage 2: Tighten to ............................................... ............................................................................................................................... 71 Nm (52 ft. lbs.). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 5404 Flex Plate: Service and Repair Flexplate Flexplate Removal 1. Remove the transmission. 2. Remove the bolts and the flexplate. Installation 1. NOTE: Special bolts are used for flexplate installation. Do not use standard bolts. Install the flexplate. Tighten the bolts in 2 stages in the sequence shown. ^ Stage 1: Tighten to 13 Nm (10 ft. lbs.). ^ Stage 2: Tighten to 71 Nm (52 ft. lbs.). 2. Install the transmission. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 (TCIL) The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Description and Operation Power Take-Off: Description and Operation POWER TAKE-OFF (PTO) SWITCH AND CIRCUITS The PTO circuit is used by the PCM to disable some of the on board diagnostics (OBD) monitors during PTO operation. The PTO switch is normally open. When the PTO unit is activated, the PTO switch is closed and battery voltage is supplied to the PTO input circuit. This indicates to the PCM that an additional load is being applied to the engine. The PTO indicator lamp illuminates when the PTO system is functioning correctly and flashes when the PTO system is damaged When the PTO unit is activated, the PCM disables some OBD monitors, which may not function reliably during PTO operation. Without the PTO circuit information to the PCM, false DTCs may be set during PTO operation. Prior to an Inspection/Maintenance test, operate the vehicle with the PTO disengaged long enough to successfully complete the OBD Monitors. PTO Circuits Description The 3 PTO input circuits are PTO mode, PTO engage, and PTO RPM. The PTO engage circuit is used when the operator is requesting the PCM to check the needed inputs required to initiate the PTO engagement. The PTO RPM circuit is used for the operator to request additional engine RPM for PTO operation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM Control Module: Customer Interest A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM TSB 07-6-3 04/02/07 6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac MERCURY: 2006-2007 Mountaineer ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition vehicles may exhibit the following diagnostic trouble codes in the transmission control module (1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657, P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083, P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination at the mechatronic assembly. ACTION Follow the Service Procedure steps to correct the condition. NOTE IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM BARRIER STRIP. SERVICE PROCEDURE Remove the source of contamination from the transmission control unit (TCU)/solenoid connections and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent recurrence. 1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01. 2. Remove the six (6) long fasteners from the TCM unit. (Figure 1) 3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of the main control during this procedure. NOTE IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS SYSTEM. 4. Inspect the TCM at the following locations for metal chips or other metallic contamination. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5423 a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination. (Figure 2) b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure 3 and 4) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5424 c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure 5) 5. Prior to installation of the protective strip, remove all machining chips and or other metallic contamination from these areas with a clean, lint free cloth. 6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam barrier strip is installed). 7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first, "point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM, Section 307-01. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5425 8. Reinstall the mechatronic assembly following the WSM, Section 307-01. 9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01. 10. Set the transmission fluid level following the WSM, Section 307-01. 11. Clear all DTC(s) from the TCM. 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 070603A 2006-2007 2.6 Hrs. Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) 070603A 2007 Expedition 6R75 2.7 Hrs. Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) DEALER CODING CONDITION BASIC PART NO. CODE 14B167 49 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM Control Module: All Technical Service Bulletins A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM TSB 07-6-3 04/02/07 6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac MERCURY: 2006-2007 Mountaineer ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition vehicles may exhibit the following diagnostic trouble codes in the transmission control module (1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657, P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083, P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination at the mechatronic assembly. ACTION Follow the Service Procedure steps to correct the condition. NOTE IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM BARRIER STRIP. SERVICE PROCEDURE Remove the source of contamination from the transmission control unit (TCU)/solenoid connections and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent recurrence. 1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01. 2. Remove the six (6) long fasteners from the TCM unit. (Figure 1) 3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of the main control during this procedure. NOTE IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS SYSTEM. 4. Inspect the TCM at the following locations for metal chips or other metallic contamination. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5431 a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination. (Figure 2) b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure 3 and 4) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5432 c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure 5) 5. Prior to installation of the protective strip, remove all machining chips and or other metallic contamination from these areas with a clean, lint free cloth. 6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam barrier strip is installed). 7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first, "point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM, Section 307-01. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5433 8. Reinstall the mechatronic assembly following the WSM, Section 307-01. 9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01. 10. Set the transmission fluid level following the WSM, Section 307-01. 11. Clear all DTC(s) from the TCM. 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 070603A 2006-2007 2.6 Hrs. Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) 070603A 2007 Expedition 6R75 2.7 Hrs. Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) DEALER CODING CONDITION BASIC PART NO. CODE 14B167 49 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions Brake Switch - TCC: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5440 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5441 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5442 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5443 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5444 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5445 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5446 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5447 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5448 Brake Switch - TCC: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5449 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5450 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5451 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5452 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5453 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5454 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5455 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5456 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Page 5457 Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Overdrive Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5462 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5463 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5464 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5465 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5466 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5467 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5468 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5469 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5470 Overdrive Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5471 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5472 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5473 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5474 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5475 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5476 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5477 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5478 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor/Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5483 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5484 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5485 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5486 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5487 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5488 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5489 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5490 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5491 Throttle Position Sensor/Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5492 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5493 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5494 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5495 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5496 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5497 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5498 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5499 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Mode Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5504 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5505 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5506 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5507 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5508 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5509 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5510 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5511 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5512 Transmission Mode Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5513 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5514 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5515 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5516 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5517 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5518 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5519 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5520 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Control (TC) Switch Transmission Mode Switch: Description and Operation Transmission Control (TC) Switch Transmission Control (TC) Switch The transmission control (TC) switch is a momentary contact switch located on the selector lever knob. Pushing the TC switch will either disengage or engage the overdrive function of the transmission. If OVERDRIVE is disengaged, the message O/D OFF will illuminate on the instrument panel. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Control (TC) Switch > Page 5523 Transmission Mode Switch: Description and Operation Transmission Control Switch (TCS) TRANSMISSION CONTROL SWITCH (TCS) Typical Transmission Control Switch (TCS) Typical Transmission Control Switch (TCS) The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature, the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage overdrive. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Page 5524 Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch Removal 1. Remove the transmission selector lever knob. 2. Remove the transmission control switch from the knob. Installation 1. Install the transmission control switch into the knob. 2. Install the transmission selector lever knob. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5530 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5531 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5532 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5533 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5534 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5535 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5536 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5537 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5538 Transmission Position Switch/Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5539 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5540 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5541 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5542 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5543 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5544 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5545 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5546 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5547 C167 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5548 Transmission Position Switch/Sensor: Testing and Inspection Digital Transmission Range (TR) Sensor Diagnosis Chart Digital Transmission Range (TR) Sensor Diagnosis Chart Wiggle Test Information for Open/Shorts ^ TR4, TR3A, TR2 and TR1 are all closed in PARK. PARK is a good position to check for intermittent open circuits (with scan tool monitoring TRD). ^ TR4, TR3A, TR2 and TR1 are all open in OVERDRIVE, so OVERDRIVE is a good position to check for shorts to ground. To determine the shorted components while observing TRD, unplug the TR and determine if the short goes away. If the short is still present unplug the transmission harness and determine if the short goes away. If the short is still present, then the short is in the PCM or vehicle harness. Remove the suspect circuit(s) wire terminal from the PCM connector. If the short is still present, then the PCM has an internal failure, otherwise the failure is in the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5549 Transmission Position Switch/Sensor: Adjustments Transmission Range (TR) Sensor Adjustment Special Tool(s) Adjust 1. With the vehicle in NEUTRAL, position it on a hoist For additional information, refer to Maintenance/Service and Repair. 2. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the connector. 4. Disconnect the digital transmission range (TR) sensor electrical connector. 5. Remove the range selector lever cable end from the manual control lever. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5550 6. Remove the outer manual control lever. 7. Loosen but do not remove the digital TR sensor screws. 8. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. ^ Tighten to 8 Nm (71 inch lbs.) 9. Install the outer manual lever. ^ Tighten to 48 Nm (35 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5551 10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable end onto the manual control lever. 11. Reconnect the digital TR sensor electrical connector. 12. Move the rubber boot back over the connector. 13. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5552 14. Verify that the selector lever cable is adjusted correctly. 15. Verify that the vehicle will start in PARK and NEUTRAL and that the reverse lamps illuminate in REVERSE. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5553 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the connector. 4. Disconnect the digital transmission range (TR) sensor electrical connector. 5. Remove the selector lever cable from the manual control lever. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5554 6. Remove the outer manual control lever. 7. Remove the digital TR sensor. Installation 1. CAUTION: The digital transmission range sensor must fit flush against the boss on the case to prevent damage to the sensor. Install the digital TR sensor and 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 be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5555 ^ Tighten to 8 Nm (71 inch lbs.) 3. Install the outer manual lever. ^ Tighten to 48 Nm (35 ft. lbs.) 4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable to the manual control lever. 5. Connect the digital TR sensor electrical connector. 6. Move the rubber boot back over the connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5556 7. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. 8. Verify that the selector lever cable is adjusted correctly. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 5561 View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 5562 View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5565 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5566 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5567 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5568 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5569 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5570 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5571 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5572 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5573 Transmission Speed Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5574 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5575 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5576 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5577 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5578 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5579 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5580 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5581 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5582 Transmission Speed Sensor: Connector Views C193 C143 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5583 C164 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 5586 6. Remove the selector lever cable and bracket. 7. Disconnect the turbine shaft speed (TSS) sensor electrical connector. 8. Remove the TSS sensor. 1 Remove the TSS sensor screw. 2 Remove the TSS sensor from the transmission. ^ Inspect the TSS sensor O-ring for damage. If damaged, install a new O-ring. Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the TSS sensor into the transmission. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 5587 2 Tighten the TSS sensor screw. ^ Tighten to 14 Nm (10 ft. lbs.) 2. Connect the TSS sensor electrical connector. 3. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable and bracket. ^ Tighten to 40 Nm (30 ft. lbs.) 4. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 5588 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Install the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 ft. lbs.) 7. Install the front driveshaft to the front differential. ^ Tighten to 18 Nm (13 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 5589 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 5590 6. Remove the selector lever cable and bracket. 7. Disconnect the heated oxygen sensor (HO2S) sensor connector from the transmission case. 8. Disconnect the output shaft speed (OSS) sensor electrical connector. 9. Remove the 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, install a new O-ring. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 5591 Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the OSS sensor into the transmission. 2 Tighten the OSS sensor screw. ^ Tighten to 14 Nm (10 ft. lbs.) 2. Connect the OSS sensor electrical connector. 3. Connect the HO2S connector to the transmission case. 4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 5592 cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable and bracket. ^ Tighten to 40 Nm (30 ft. lbs.) 5. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. 4WD vehicles 6. Install the front driveshaft in the vehicle. 7. Install the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 5593 8. Install the front driveshaft to the front differential. ^ Tighten to 18 Nm (13 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 5594 Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor Intermediate Shaft Speed Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 5595 6. Remove the selector lever cable and bracket. 7. Disconnect the intermediate shaft speed sensor electrical connector. 8. Remove the intermediate shaft speed sensor. 1 Remove the intermediate shaft speed sensor screw. 2 Remove the intermediate shaft speed sensor from the transmission. ^ Inspect the intermediate shaft speed sensor O-ring for damage. If damaged, install a new O-ring. Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the intermediate shaft speed sensor into the transmission. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 5596 2 Tighten the intermediate shaft speed sensor screw. ^ Tighten to 14 Nm (10 ft. lbs.) 2. Connect the intermediate shaft speed sensor electrical connector. 3. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable and bracket. ^ Tighten to 40 Nm (30 ft. lbs.) 4. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 5597 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Install the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 ft. lbs.) 7. Install the front driveshaft to the front differential. ^ Tighten to 18 Nm (13 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5602 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5603 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5604 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5605 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5606 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5607 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5608 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5609 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5610 Transmission Temperature Sensor/Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5611 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5612 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5613 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5614 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5615 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5616 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5617 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5618 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Specifications Pressure Regulating Solenoid: Specifications Solenoid Operation Chart Solenoid Operation Chart Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5627 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5628 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5629 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5630 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5631 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5632 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5633 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5634 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5635 Pressure Regulating Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5636 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5637 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5638 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5639 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5640 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5641 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5642 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5643 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5644 Pressure Regulating Solenoid: Testing and Inspection Pinpoint Tests - OSC Equipped Vehicle Special Tool(s) (Part 1) Special Tool(s) (Part 2) Shift Solenoid Pre-Diagnosis Any time an electrical connector or solenoid body is disconnected, inspect the connector for terminal condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install new as necessary. Use this shift solenoid operation information when carrying out Pinpoint Test A. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5645 Solenoid Operation Chart (Part 1) Solenoid Operation Chart (Part 2) Shift Solenoid Failure Mode Chart Failed ON or OFF due to powertrain control module (PCM) and/or vehicle wiring concerns, solenoid electrically, mechanically or hydraulically stuck ON or OFF. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5646 SSA, SSB SSC, SSD Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5647 PC A, PC B, PC C (Part 1) PC A, PC B, PC C (Part 2) PC A, PC B, PC C (Part 3) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5648 Pressure Regulating Solenoid: Service and Repair Solenoid Body Assembly Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the drain plug and drain the fluid. 3. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. Disconnect the solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the gasket should be reused. Remove the 16 transmission fluid pan screws, fluid pan and gasket. 5. Remove the transmission fluid filter. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5649 6. CAUTION: Do not damage the solenoid body connector pins. Remove the solenoid body bolts and remove the solenoid body by pulling down on the solenoid body and pushing down on the connector from the other side of the case. Installation 1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean automatic transmission fluid. 2. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur. Install the solenoid body. Tighten the bolts in sequence shown. ^ Tighten to 8 Nm (71 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5650 3. CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be damaged. NOTE: Make sure that the fluid filter seals are correctly seated on the filter. Lubricate the seals and install the transmission fluid filter. ^ Tighten to 10 Nm (89 inch lbs.) 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage, if not damaged, the gasket should be reused. Install the transmission fluid pan and gasket and loosely install the screws. 5. Tighten the screws in a crisscross sequence. ^ Tighten to 11 Nm (8 ft. lbs.) 6. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the specification. NOTE: Always install new O-ring seals on vehicle harness connector. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission connector and connect the connector. ^ Tighten to 5 Nm (44 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5651 7. Fill the transmission. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Service and Repair Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Brake Shift Interlock Actuator Removal 1. Remove the front floor console. For additional information, refer to Console. 2. Disconnect the brake shift lock actuator electrical connector. 3. Remove the screw and the brake shift lock actuator. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Service and Repair > Page 5655 Installation 1. Install the brake shift lock actuator. 2. Connect the brake shift lock actuator electrical connector. 3. Install the front floor console. For additional information, refer to Console. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Specifications Shift Solenoid: Specifications Solenoid Operation Chart Solenoid Operation Chart Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5661 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5662 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5663 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5664 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5665 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5666 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5667 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5668 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5669 Shift Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5670 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5671 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5672 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5673 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5674 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5675 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5676 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5677 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5678 Shift Solenoid: Testing and Inspection Pinpoint Tests - OSC Equipped Vehicle Special Tool(s) (Part 1) Special Tool(s) (Part 2) Shift Solenoid Pre-Diagnosis Any time an electrical connector or solenoid body is disconnected, inspect the connector for terminal condition, corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install new as necessary. Use this shift solenoid operation information when carrying out Pinpoint Test A. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5679 Solenoid Operation Chart (Part 1) Solenoid Operation Chart (Part 2) Shift Solenoid Failure Mode Chart Failed ON or OFF due to powertrain control module (PCM) and/or vehicle wiring concerns, solenoid electrically, mechanically or hydraulically stuck ON or OFF. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5680 SSA, SSB SSC, SSD Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5681 PC A, PC B, PC C (Part 1) PC A, PC B, PC C (Part 2) PC A, PC B, PC C (Part 3) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5682 Shift Solenoid: Service and Repair Solenoid Body Assembly Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the drain plug and drain the fluid. 3. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. Disconnect the solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the gasket should be reused. Remove the 16 transmission fluid pan screws, fluid pan and gasket. 5. Remove the transmission fluid filter. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5683 6. CAUTION: Do not damage the solenoid body connector pins. Remove the solenoid body bolts and remove the solenoid body by pulling down on the solenoid body and pushing down on the connector from the other side of the case. Installation 1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean automatic transmission fluid. 2. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur. Install the solenoid body. Tighten the bolts in sequence shown. ^ Tighten to 8 Nm (71 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5684 3. CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be damaged. NOTE: Make sure that the fluid filter seals are correctly seated on the filter. Lubricate the seals and install the transmission fluid filter. ^ Tighten to 10 Nm (89 inch lbs.) 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage, if not damaged, the gasket should be reused. Install the transmission fluid pan and gasket and loosely install the screws. 5. Tighten the screws in a crisscross sequence. ^ Tighten to 11 Nm (8 ft. lbs.) 6. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the specification. NOTE: Always install new O-ring seals on vehicle harness connector. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission connector and connect the connector. ^ Tighten to 5 Nm (44 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5685 7. Fill the transmission. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Solenoid Operation Chart Solenoid Operation Chart Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5691 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5692 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5693 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5694 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5695 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5696 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5697 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5698 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5699 Torque Converter Clutch Solenoid: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5700 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5701 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5702 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5703 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5704 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5705 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5706 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5707 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5708 Torque Converter Clutch Solenoid: Service and Repair Solenoid Body Assembly Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the drain plug and drain the fluid. 3. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. Disconnect the solenoid body harness connector. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the gasket should be reused. Remove the 16 transmission fluid pan screws, fluid pan and gasket. 5. Remove the transmission fluid filter. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5709 6. CAUTION: Do not damage the solenoid body connector pins. Remove the solenoid body bolts and remove the solenoid body by pulling down on the solenoid body and pushing down on the connector from the other side of the case. Installation 1. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean automatic transmission fluid. 2. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur. Install the solenoid body. Tighten the bolts in sequence shown. ^ Tighten to 8 Nm (71 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5710 3. CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be damaged. NOTE: Make sure that the fluid filter seals are correctly seated on the filter. Lubricate the seals and install the transmission fluid filter. ^ Tighten to 10 Nm (89 inch lbs.) 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage, if not damaged, the gasket should be reused. Install the transmission fluid pan and gasket and loosely install the screws. 5. Tighten the screws in a crisscross sequence. ^ Tighten to 11 Nm (8 ft. lbs.) 6. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the specification. NOTE: Always install new O-ring seals on vehicle harness connector. NOTE: Clean the area around connector to prevent contamination of the solenoid body connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission connector and connect the connector. ^ Tighten to 5 Nm (44 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5711 7. Fill the transmission. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 (TCIL) The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM Control Module: Customer Interest A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM TSB 07-6-3 04/02/07 6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac MERCURY: 2006-2007 Mountaineer ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition vehicles may exhibit the following diagnostic trouble codes in the transmission control module (1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657, P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083, P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination at the mechatronic assembly. ACTION Follow the Service Procedure steps to correct the condition. NOTE IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM BARRIER STRIP. SERVICE PROCEDURE Remove the source of contamination from the transmission control unit (TCU)/solenoid connections and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent recurrence. 1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01. 2. Remove the six (6) long fasteners from the TCM unit. (Figure 1) 3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of the main control during this procedure. NOTE IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS SYSTEM. 4. Inspect the TCM at the following locations for metal chips or other metallic contamination. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5727 a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination. (Figure 2) b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure 3 and 4) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5728 c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure 5) 5. Prior to installation of the protective strip, remove all machining chips and or other metallic contamination from these areas with a clean, lint free cloth. 6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam barrier strip is installed). 7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first, "point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM, Section 307-01. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5729 8. Reinstall the mechatronic assembly following the WSM, Section 307-01. 9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01. 10. Set the transmission fluid level following the WSM, Section 307-01. 11. Clear all DTC(s) from the TCM. 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 070603A 2006-2007 2.6 Hrs. Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) 070603A 2007 Expedition 6R75 2.7 Hrs. Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) DEALER CODING CONDITION BASIC PART NO. CODE 14B167 49 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM Control Module: All Technical Service Bulletins A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM TSB 07-6-3 04/02/07 6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac MERCURY: 2006-2007 Mountaineer ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition vehicles may exhibit the following diagnostic trouble codes in the transmission control module (1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657, P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083, P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination at the mechatronic assembly. ACTION Follow the Service Procedure steps to correct the condition. NOTE IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM BARRIER STRIP. SERVICE PROCEDURE Remove the source of contamination from the transmission control unit (TCU)/solenoid connections and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent recurrence. 1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01. 2. Remove the six (6) long fasteners from the TCM unit. (Figure 1) 3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of the main control during this procedure. NOTE IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS SYSTEM. 4. Inspect the TCM at the following locations for metal chips or other metallic contamination. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5735 a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination. (Figure 2) b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure 3 and 4) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5736 c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure 5) 5. Prior to installation of the protective strip, remove all machining chips and or other metallic contamination from these areas with a clean, lint free cloth. 6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam barrier strip is installed). 7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first, "point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM, Section 307-01. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5737 8. Reinstall the mechatronic assembly following the WSM, Section 307-01. 9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01. 10. Set the transmission fluid level following the WSM, Section 307-01. 11. Clear all DTC(s) from the TCM. 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 070603A 2006-2007 2.6 Hrs. Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) 070603A 2007 Expedition 6R75 2.7 Hrs. Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84) DEALER CODING CONDITION BASIC PART NO. CODE 14B167 49 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions Brake Switch - TCC: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5744 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5745 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5746 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5747 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5748 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5749 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5750 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5751 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5752 Brake Switch - TCC: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5753 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5754 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5755 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5756 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5757 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5758 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5759 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 5760 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Page 5761 Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Overdrive Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5766 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5767 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5768 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5769 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5770 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5771 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5772 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5773 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5774 Overdrive Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5775 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5776 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5777 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5778 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5779 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5780 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5781 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5782 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor/Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5787 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5788 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5789 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5790 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5791 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5792 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5793 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5794 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5795 Throttle Position Sensor/Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5796 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5797 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5798 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5799 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5800 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5801 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5802 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5803 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions Transmission Mode Switch: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 5808 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 5809 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 5810 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 5811 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 5812 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 5813 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 5814 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 5815 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 5816 Transmission Mode Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 5817 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 5818 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 5819 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 5820 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 5821 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 5822 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 5823 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Diagrams > Diagram Information and Instructions > Page 5824 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Control (TC) Switch Transmission Mode Switch: Description and Operation Transmission Control (TC) Switch Transmission Control (TC) Switch The transmission control (TC) switch is a momentary contact switch located on the selector lever knob. Pushing the TC switch will either disengage or engage the overdrive function of the transmission. If OVERDRIVE is disengaged, the message O/D OFF will illuminate on the instrument panel. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Control (TC) Switch > Page 5827 Transmission Mode Switch: Description and Operation Transmission Control Switch (TCS) TRANSMISSION CONTROL SWITCH (TCS) Typical Transmission Control Switch (TCS) Typical Transmission Control Switch (TCS) The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature, the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage overdrive. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Page 5828 Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch Removal 1. Remove the transmission selector lever knob. 2. Remove the transmission control switch from the knob. Installation 1. Install the transmission control switch into the knob. 2. Install the transmission selector lever knob. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5834 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5835 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5836 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5837 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5838 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5839 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5840 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5841 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5842 Transmission Position Switch/Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5843 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5844 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5845 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5846 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5847 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5848 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5849 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5850 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5851 C167 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5852 Transmission Position Switch/Sensor: Testing and Inspection Digital Transmission Range (TR) Sensor Diagnosis Chart Digital Transmission Range (TR) Sensor Diagnosis Chart Wiggle Test Information for Open/Shorts ^ TR4, TR3A, TR2 and TR1 are all closed in PARK. PARK is a good position to check for intermittent open circuits (with scan tool monitoring TRD). ^ TR4, TR3A, TR2 and TR1 are all open in OVERDRIVE, so OVERDRIVE is a good position to check for shorts to ground. To determine the shorted components while observing TRD, unplug the TR and determine if the short goes away. If the short is still present unplug the transmission harness and determine if the short goes away. If the short is still present, then the short is in the PCM or vehicle harness. Remove the suspect circuit(s) wire terminal from the PCM connector. If the short is still present, then the PCM has an internal failure, otherwise the failure is in the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5853 Transmission Position Switch/Sensor: Adjustments Transmission Range (TR) Sensor Adjustment Special Tool(s) Adjust 1. With the vehicle in NEUTRAL, position it on a hoist For additional information, refer to Maintenance/Service and Repair. 2. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the connector. 4. Disconnect the digital transmission range (TR) sensor electrical connector. 5. Remove the range selector lever cable end from the manual control lever. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5854 6. Remove the outer manual control lever. 7. Loosen but do not remove the digital TR sensor screws. 8. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. ^ Tighten to 8 Nm (71 inch lbs.) 9. Install the outer manual lever. ^ Tighten to 48 Nm (35 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5855 10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable end onto the manual control lever. 11. Reconnect the digital TR sensor electrical connector. 12. Move the rubber boot back over the connector. 13. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5856 14. Verify that the selector lever cable is adjusted correctly. 15. Verify that the vehicle will start in PARK and NEUTRAL and that the reverse lamps illuminate in REVERSE. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5857 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the connector. 4. Disconnect the digital transmission range (TR) sensor electrical connector. 5. Remove the selector lever cable from the manual control lever. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5858 6. Remove the outer manual control lever. 7. Remove the digital TR sensor. Installation 1. CAUTION: The digital transmission range sensor must fit flush against the boss on the case to prevent damage to the sensor. Install the digital TR sensor and 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 be in the NEUTRAL position. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5859 ^ Tighten to 8 Nm (71 inch lbs.) 3. Install the outer manual lever. ^ Tighten to 48 Nm (35 ft. lbs.) 4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable to the manual control lever. 5. Connect the digital TR sensor electrical connector. 6. Move the rubber boot back over the connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5860 7. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. 8. Verify that the selector lever cable is adjusted correctly. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Locations > Output Shaft Speed (OSS) Sensor View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Locations > Output Shaft Speed (OSS) Sensor > Page 5865 View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Locations > Output Shaft Speed (OSS) Sensor > Page 5866 View 151-6 (Engine, Rear - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5869 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5870 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5871 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5872 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5873 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5874 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5875 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5876 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5877 Transmission Speed Sensor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5878 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5879 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5880 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5881 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5882 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5883 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5884 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5885 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5886 Transmission Speed Sensor: Connector Views C193 C143 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5887 C164 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 5890 6. Remove the selector lever cable and bracket. 7. Disconnect the turbine shaft speed (TSS) sensor electrical connector. 8. Remove the TSS sensor. 1 Remove the TSS sensor screw. 2 Remove the TSS sensor from the transmission. ^ Inspect the TSS sensor O-ring for damage. If damaged, install a new O-ring. Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the TSS sensor into the transmission. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 5891 2 Tighten the TSS sensor screw. ^ Tighten to 14 Nm (10 ft. lbs.) 2. Connect the TSS sensor electrical connector. 3. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable and bracket. ^ Tighten to 40 Nm (30 ft. lbs.) 4. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 5892 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Install the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 ft. lbs.) 7. Install the front driveshaft to the front differential. ^ Tighten to 18 Nm (13 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 5893 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 5894 6. Remove the selector lever cable and bracket. 7. Disconnect the heated oxygen sensor (HO2S) sensor connector from the transmission case. 8. Disconnect the output shaft speed (OSS) sensor electrical connector. 9. Remove the 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, install a new O-ring. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 5895 Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the OSS sensor into the transmission. 2 Tighten the OSS sensor screw. ^ Tighten to 14 Nm (10 ft. lbs.) 2. Connect the OSS sensor electrical connector. 3. Connect the HO2S connector to the transmission case. 4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 5896 cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable and bracket. ^ Tighten to 40 Nm (30 ft. lbs.) 5. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. 4WD vehicles 6. Install the front driveshaft in the vehicle. 7. Install the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 5897 8. Install the front driveshaft to the front differential. ^ Tighten to 18 Nm (13 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 5898 Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor Intermediate Shaft Speed Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. Four wheel drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 5899 6. Remove the selector lever cable and bracket. 7. Disconnect the intermediate shaft speed sensor electrical connector. 8. Remove the intermediate shaft speed sensor. 1 Remove the intermediate shaft speed sensor screw. 2 Remove the intermediate shaft speed sensor from the transmission. ^ Inspect the intermediate shaft speed sensor O-ring for damage. If damaged, install a new O-ring. Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1 Install the intermediate shaft speed sensor into the transmission. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 5900 2 Tighten the intermediate shaft speed sensor screw. ^ Tighten to 14 Nm (10 ft. lbs.) 2. Connect the intermediate shaft speed sensor electrical connector. 3. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the cable end is correctly installed. Install the selector lever cable and bracket. ^ Tighten to 40 Nm (30 ft. lbs.) 4. NOTE: If the shield is loose on the cable, replace the shield. Install the cable shield. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 > Turbine Shaft Speed (TSS) Sensor > Page 5901 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Install the front driveshaft to the transfer case. ^ Tighten to 30 Nm (22 ft. lbs.) 7. Install the front driveshaft to the front differential. ^ Tighten to 18 Nm (13 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5906 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5907 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5908 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5909 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5910 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5911 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5912 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5913 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5914 Transmission Temperature Sensor/Switch: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5915 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5916 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5917 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5918 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5919 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5920 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5921 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 5922 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Sensor Block > Component Information > Service and Repair ABS Sensor Block: Service and Repair Stability Control Sensor Cluster Stability Control Sensor Cluster Removal and Installation NOTE: When installing a new stability control sensor cluster, the anti-lock brake system (ABS) module must be calibrated. Follow the scan tool directions for the calibration procedures. 1. Remove the pin-type retainer and the driver side floor console finish panel. 2. Remove the 2 bolts, 2 nuts and the LH instrument panel brace. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Sensor Block > Component Information > Service and Repair > Page 5928 ^ To install, tighten to 9 Nm (80 inch lbs.). 3. Remove the 2 screws and LH heater duct. 4. Disconnect the stability control sensor cluster electrical connector. 5. Remove the stability control sensor cluster electrical harness retainers and position aside. 6. Remove the 2 stability control sensor cluster bracket nuts and the stability control sensor cluster. ^ To install, tighten to 7 Nm (62 inch lbs.). 7. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations View 151-2 (Engine Compartment - 4.0L, (2 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 5932 C155 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 5933 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System (ABS) Module Material Removal and Installation WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in personal injury. 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: Electronic modules are sensitive to electrical charges. The ABS module can be damaged if exposed to these charges. NOTE: When installing a new ABS module, it must be configured (using vehicle as-built data) and calibrated. Follow the scan tool directions for the calibration procedures. For module configuration, refer to Information Bus. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 5934 1. Remove the hydraulic control unit (HCU). 2. CAUTION: Make sure that the ABS module is properly seated to the HCU and that the torque of the ABS module screws is correct, or damage to the components can occur. Remove the 4 screws and the ABS module. ^ To install, tighten to 2 Nm (18 inch lbs.). 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Procedures Hydraulic Control Assembly - Antilock Brakes: Procedures Anti-Lock Brake System (ABS) Hydraulic Control Unit (HCU) Bleeding NOTE: This procedure is required only when a new HCU is installed. 1. Connect the scan tool and follow the ABS bleed instructions. 2. Use the caliper bleed procedure to bleed the system. Begin at the RH rear caliper. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Procedures > Page 5939 Hydraulic Control Assembly - Antilock Brakes: Removal and Replacement Hydraulic Control Unit (HCU) Material Removal and Installation WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in personal injury. 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Procedures > Page 5940 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair 2. Remove the battery tray. 3. Disconnect the anti-lock brake system (ABS) module electrical connector. 4. NOTE: The brake tubes must be installed in the same location as removed. Remove the 2 brake tube-to-hydraulic control unit (HCU) fittings and position the brake tubes aside. ^ To install, tighten to 23 Nm (17 ft. lbs.). 5. NOTE: The brake tubes must be installed in the same location as removed. Remove the 4 brake tube-to-HCU extension tube fittings. ^ To install, tighten to 18 Nm (13 ft. lbs.). 6. Remove the 3 HCU bracket-to-frame nuts. ^ To install, tighten to 23 Nm (17 ft. lbs.). 7. Remove the HCU assembly. 8. NOTE: The brake tubes must be installed in the same location as removed. Remove the 4 HCU extension tube-to-HCU fittings. ^ To install, tighten to 18 Nm (13 ft. lbs.). 9. Remove the 2 HCU bracket-to-HCU extension tube retainer nuts and the extension tube retainer assembly. ^ To install, tighten to 9 Nm (80 inch lbs.). 10. Remove the bracket-to-HCU bolts and the HCU bracket. ^ To install, tighten to 9 Nm (80 inch lbs.). 11. To install, reverse the removal procedure. ^ Bleed the brake system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Service and Repair Lateral Accelerometer: Service and Repair Stability Control Sensor Cluster Stability Control Sensor Cluster Removal and Installation NOTE: When installing a new stability control sensor cluster, the anti-lock brake system (ABS) module must be calibrated. Follow the scan tool directions for the calibration procedures. 1. Remove the pin-type retainer and the driver side floor console finish panel. 2. Remove the 2 bolts, 2 nuts and the LH instrument panel brace. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Service and Repair > Page 5944 ^ To install, tighten to 9 Nm (80 inch lbs.). 3. Remove the 2 screws and LH heater duct. 4. Disconnect the stability control sensor cluster electrical connector. 5. Remove the stability control sensor cluster electrical harness retainers and position aside. 6. Remove the 2 stability control sensor cluster bracket nuts and the stability control sensor cluster. ^ To install, tighten to 7 Nm (62 inch lbs.). 7. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Service and Repair Steering Angle Sensor: Service and Repair Steering Wheel Rotation Sensor Steering Wheel Rotation Sensor Removal and Installation 1. Remove the 3 lower steering column cover bolts and the lower steering column cover. 2. Remove the upper steering column cover. 3. Disconnect the steering wheel rotation sensor electrical connector. 4. Remove the 2 bolts and the steering wheel rotation sensor. 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations View 151-11 (behind Dash Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Page 5951 C280 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Page 5952 Traction Control Switch: Service and Repair Stability/Traction Control Switch Removal and Installation 1. Remove the 2 floor console center finish panel screws and the floor console center finish panel. ^ To install, tighten to 9 Nm (80 inch lbs.). 2. Apply the parking brake. 3. Move the gear selector lever to the D1 position. 4. Position the instrument panel center finish panel away from the instrument panel. 5. Disconnect the stability traction control switch electrical connector and remove the stability traction control switch from the instrument panel Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Page 5953 center finish panel. 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left/Right Front View 151-2 (Engine Compartment - 4.0L, (2 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left/Right Front > Page 5958 View 151-15 (Left Rear, (1 0f 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left/Right Front > Page 5959 View 151-17 (Right Rear, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front C150 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 5962 C440 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 5963 C160 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 5964 C426 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Front Wheel Speed Sensor - Front Wheel Speed Sensor - Front Removal and Installation 1. Remove the front brake disc. 2. Disconnect the wheel speed sensor electrical connector. 3. Remove the wheel speed sensor harness bolt. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 5967 4. Remove the wheel speed sensor harness pin-type retainers. 5. Remove the wheel speed sensor bolt. ^ To install, tighten to 17 Nm (13 ft. lbs.). 6. Remove the wheel speed sensor and the harness. 7. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 5968 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Rear Wheel Speed Sensor - Rear Wheel Speed Sensor - Rear Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair 2. Disconnect the wheel speed sensor electrical connector. 3. Disconnect the wheel speed harness from the retainers. 4. Remove the wheel speed sensor bolt and the wheel speed sensor. ^ To install, tighten to 8 Nm (71 inch lbs.). 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Locations View 151-12 (Center Console) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Locations > Page 5972 C3073 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Locations > Page 5973 Yaw Rate Sensor: Service and Repair Stability Control Sensor Cluster Stability Control Sensor Cluster Removal and Installation NOTE: When installing a new stability control sensor cluster, the anti-lock brake system (ABS) module must be calibrated. Follow the scan tool directions for the calibration procedures. 1. Remove the pin-type retainer and the driver side floor console finish panel. 2. Remove the 2 bolts, 2 nuts and the LH instrument panel brace. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Locations > Page 5974 ^ To install, tighten to 9 Nm (80 inch lbs.). 3. Remove the 2 screws and LH heater duct. 4. Disconnect the stability control sensor cluster electrical connector. 5. Remove the stability control sensor cluster electrical harness retainers and position aside. 6. Remove the 2 stability control sensor cluster bracket nuts and the stability control sensor cluster. ^ To install, tighten to 7 Nm (62 inch lbs.). 7. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > Customer Interest for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel Brake Bleeding: Customer Interest Brakes - Poor Brake Pedal Feel TSB 09-1-6 01/26/09 IMPROVED BRAKE PEDAL FEEL AND FIRMNESS - BUILT BEFORE 5/31/2008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-2-8 to update the part list and add a production fix date. ISSUE Some 2006-2008 Explorer, Mountaineer, and 2007-2008 Sport Trac vehicles built before 5/31/2008 may experience customer concerns with brake pedal feel or firmness. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Bleed the brake system using the anti-lock brake system (ABS) hydraulic control unit (HCU) bleeding procedure found in Workshop Manual (WSM), Section 206-00. a. If the brake bleeding procedure resolves the concern, do not continue with this TSB and return the vehicle to the customer. b. If the brake bleeding procedure does not resolve the customer concern, replace the brake pedal assembly. 2. Remove brake pedal assembly, Refer to WSM Section 206-06. 3. Install updated brake pedal assembly. Parts Block 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 090106A 2006-2008 0.7 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System (Do Not Use With 2000A) 090106B 2006-2008 1.8 Hrs. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System, Replace The Brake Pedal Assembly (Do Not Use With 2000A, Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > Customer Interest for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel > Page 5983 13480A, 9818A8) DEALER CODING CONDITION BASIC PART NO. CODE 2455 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > By Symptom for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel Brake Bleeding: By Symptom Brakes - Poor Brake Pedal Feel TSB 09-1-6 01/26/09 IMPROVED BRAKE PEDAL FEEL AND FIRMNESS - BUILT BEFORE 5/31/2008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-2-8 to update the part list and add a production fix date. ISSUE Some 2006-2008 Explorer, Mountaineer, and 2007-2008 Sport Trac vehicles built before 5/31/2008 may experience customer concerns with brake pedal feel or firmness. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Bleed the brake system using the anti-lock brake system (ABS) hydraulic control unit (HCU) bleeding procedure found in Workshop Manual (WSM), Section 206-00. a. If the brake bleeding procedure resolves the concern, do not continue with this TSB and return the vehicle to the customer. b. If the brake bleeding procedure does not resolve the customer concern, replace the brake pedal assembly. 2. Remove brake pedal assembly, Refer to WSM Section 206-06. 3. Install updated brake pedal assembly. Parts Block 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 090106A 2006-2008 0.7 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System (Do Not Use With 2000A) 090106B 2006-2008 1.8 Hrs. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System, Replace The Brake Pedal Assembly (Do Not Use With 2000A, Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > By Symptom for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel > Page 5989 13480A, 9818A8) DEALER CODING CONDITION BASIC PART NO. CODE 2455 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel Brake Bleeding: All Technical Service Bulletins Brakes - Poor Brake Pedal Feel TSB 09-1-6 01/26/09 IMPROVED BRAKE PEDAL FEEL AND FIRMNESS - BUILT BEFORE 5/31/2008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-2-8 to update the part list and add a production fix date. ISSUE Some 2006-2008 Explorer, Mountaineer, and 2007-2008 Sport Trac vehicles built before 5/31/2008 may experience customer concerns with brake pedal feel or firmness. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Bleed the brake system using the anti-lock brake system (ABS) hydraulic control unit (HCU) bleeding procedure found in Workshop Manual (WSM), Section 206-00. a. If the brake bleeding procedure resolves the concern, do not continue with this TSB and return the vehicle to the customer. b. If the brake bleeding procedure does not resolve the customer concern, replace the brake pedal assembly. 2. Remove brake pedal assembly, Refer to WSM Section 206-06. 3. Install updated brake pedal assembly. Parts Block 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 090106A 2006-2008 0.7 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System (Do Not Use With 2000A) 090106B 2006-2008 1.8 Hrs. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System, Replace The Brake Pedal Assembly (Do Not Use With 2000A, Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel > Page 5995 13480A, 9818A8) DEALER CODING CONDITION BASIC PART NO. CODE 2455 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake System Bleeding Brake Bleeding: Service and Repair Brake System Bleeding Brake System Bleeding Special Tools Material Master Cylinder Bleeding WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in personal injury. 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 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 new installation, air may get into the system and cause spongy brake pedal feel. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be gravity bled, manually bled or bled using pressure bleeding equipment. 1. NOTE: When a new brake master cylinder has been installed or the system has been emptied or partially emptied, it should be primed to prevent air from getting into the system. Disconnect the brake master cylinder tubes. 2. NOTE: Original equipment tubes are not intended to be used during this procedure. Install the 2 short brake tubes with the ends submerged in the brake master cylinder reservoir and fill the brake master cylinder reservoir with clean, specified brake fluid. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake System Bleeding > Page 5998 3. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes without air bubbles. 4. Remove the 2 short brake tubes and install the 2 master cylinder brake tubes. 5. Bleed each brake tube at the brake master cylinder as follows: 1 Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 2 Loosen the rear brake tube fitting until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the brake tube fitting. 3 Repeat this operation until clear, bubble-free fluid comes out. 4 Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front brake tube. 6. While the assistant maintains pressure on the brake pedal, tighten the master cylinder brake tubes. ^ Tighten to 18 Nm (13 ft. lbs.). Brake Caliper Bleeding NOTE: It is not necessary to bleed the entire brake system. It is possible to bleed only the opened part of the system. 1. Connect one end of a clear flexible hose to the bleeder screw. Submerge the other end in a container partially filled with clean, specified brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Open the caliper bleeder screw until brake fluid flows into the container. 4. When fluid stops flowing, close the bleeder screw. ^ Tighten to 10 Nm (89 inch lbs.) for the front brake bleeder screw and 22 Nm (16 ft. lbs.) for the rear brake bleeder screw. 5. Repeat the previous 3 steps until there are no air bubbles in the brake fluid. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake System Bleeding > Page 5999 Brake Bleeding: Service and Repair Anti-Lock Brake System (ABS) Hydraulic Control Unit (HCU) Bleeding Anti-Lock Brake System (ABS) Hydraulic Control Unit (HCU) Bleeding NOTE: This procedure is required only when a new HCU is installed. 1. Connect the scan tool and follow the ABS bleed instructions. 2. Use the caliper bleed procedure to bleed the system. Begin at the RH rear caliper. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > Customer Interest for Brake Pedal Assy: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel Brake Pedal Assy: Customer Interest Brakes - Poor Brake Pedal Feel TSB 09-1-6 01/26/09 IMPROVED BRAKE PEDAL FEEL AND FIRMNESS - BUILT BEFORE 5/31/2008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-2-8 to update the part list and add a production fix date. ISSUE Some 2006-2008 Explorer, Mountaineer, and 2007-2008 Sport Trac vehicles built before 5/31/2008 may experience customer concerns with brake pedal feel or firmness. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Bleed the brake system using the anti-lock brake system (ABS) hydraulic control unit (HCU) bleeding procedure found in Workshop Manual (WSM), Section 206-00. a. If the brake bleeding procedure resolves the concern, do not continue with this TSB and return the vehicle to the customer. b. If the brake bleeding procedure does not resolve the customer concern, replace the brake pedal assembly. 2. Remove brake pedal assembly, Refer to WSM Section 206-06. 3. Install updated brake pedal assembly. Parts Block 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 090106A 2006-2008 0.7 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System (Do Not Use With 2000A) 090106B 2006-2008 1.8 Hrs. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System, Replace The Brake Pedal Assembly (Do Not Use With 2000A, Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > Customer Interest for Brake Pedal Assy: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel > Page 6008 13480A, 9818A8) DEALER CODING CONDITION BASIC PART NO. CODE 2455 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pedal Assy: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel Brake Pedal Assy: All Technical Service Bulletins Brakes - Poor Brake Pedal Feel TSB 09-1-6 01/26/09 IMPROVED BRAKE PEDAL FEEL AND FIRMNESS - BUILT BEFORE 5/31/2008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-2-8 to update the part list and add a production fix date. ISSUE Some 2006-2008 Explorer, Mountaineer, and 2007-2008 Sport Trac vehicles built before 5/31/2008 may experience customer concerns with brake pedal feel or firmness. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Bleed the brake system using the anti-lock brake system (ABS) hydraulic control unit (HCU) bleeding procedure found in Workshop Manual (WSM), Section 206-00. a. If the brake bleeding procedure resolves the concern, do not continue with this TSB and return the vehicle to the customer. b. If the brake bleeding procedure does not resolve the customer concern, replace the brake pedal assembly. 2. Remove brake pedal assembly, Refer to WSM Section 206-06. 3. Install updated brake pedal assembly. Parts Block 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 090106A 2006-2008 0.7 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System (Do Not Use With 2000A) 090106B 2006-2008 1.8 Hrs. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System, Replace The Brake Pedal Assembly (Do Not Use With 2000A, Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pedal Assy: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel > Page 6014 13480A, 9818A8) DEALER CODING CONDITION BASIC PART NO. CODE 2455 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service Bulletins > Page 6015 Brake Pedal Assy: Description and Operation Adjustable Pedals Using the adjustable pedal switch located on the instrument panel, the driver can adjust the brake and accelerator pedals for a more comfortable driving position. For removal and installation of the adjustable pedals, refer to Brake Pedal and Bracket. Adjustable Pedal Operation The adjustable pedals with or without memory feature are operational with the ignition switch in the ON or OFF position. The pedals are adjusted forward or rearward using the adjustable pedal switch. Memory Adjustable Pedal Operation The adjustable pedals with memory feature is controlled by using the memory switches or the remote keyless entry (RKE) transmitter. The exterior mirror and power driver seat positions are also stored and recalled with the power adjustable pedal positions. The system can store 3 memory settings. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake Pedal and Bracket Brake Pedal Assy: Service and Repair Brake Pedal and Bracket Brake Pedal and Bracket NOTE: Adjustable pedals shown, fixed pedals similar. Note: Adjustable Pedals Shown, Fixed Pedals Similar. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake Pedal and Bracket > Page 6018 Removal 1. NOTE: If equipped with adjustable pedals, when removing the adjustable pedal assembly, make sure the pedals are adjusted to the full forward position. Depower the supplemental restraint system (SRS). For additional information, refer to Air Bag Systems. 2. CAUTION: The brake pedal must be connected to the booster rod, in an at-rest position, before removing the stoplamp switch and speed control deactivator switch or the switch will be damaged. Remove the stoplamp switch. 3. Remove the speed control deactivator switch. For additional information, refer to Heating and Air Conditioning. 4. NOTE: The booster push rod clevis locking pin is a one-time use only part. Anytime the booster push rod clevis locking pin is removed, a new booster push rod clevis locking pin should be used. NOTE: Remove the clevis locking pin by squeezing the locking tabs and pulling outward on the opposite end. Remove the booster push rod clevis locking pin and discard. 5. Disconnect the brake booster rod from the brake pedal and position aside. 6. If equipped with power adjustable pedals, disconnect the adjustable pedal motor electrical connector. 7. If equipped with adjustable pedals, disconnect the accelerator pedal motor electrical connector. 8. Remove and discard the 2 brake pedal bracket bolts. 9. Remove and discard the 4 brake booster nuts. 10. Position the brake master cylinder and brake booster assembly forward to allow the brake pedal assembly to clear the studs. 11. Remove the 3 accelerator pedal bracket nuts. 12. Remove the 2 steering column opening cover screws and the steering column opening cover panel. 13. CAUTION: Do not allow the steering wheel to rotate while the steering column intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence the steering column shaft has rotated, the clockspring must be removed and centered. For additional information, refer to Air Bag Systems. Secure the steering wheel using a suitable holding device. 14. Remove the steering column shaft bolt and separate the steering shafts. 15. Remove the brake pedal assembly from the vehicle. Installation 1. Position the brake pedal assembly in the vehicle. 2. Position the brake master cylinder and brake booster assembly into the brake pedal bracket assembly. 3. Install the 4 new brake booster nuts. ^ Tighten to 22 Nm (16 ft. lbs.). 4. Install the 2 brake pedal bracket bolts. ^ Tighten to 22 Nm (16 ft. lbs.). 5. Install the 3 accelerator pedal bracket nuts. ^ Tighten to 7 Nm (62 inch lbs.). 6. If equipped with power adjustable pedals, connect the adjustable pedal motor electrical connector. 7. If equipped with adjustable pedals, connect the accelerator pedal electrical connector. 8. Position the brake booster push rod to the brake pedal. 9. Install the new booster push rod clevis locking pin. 10. Connect the steering shafts and install the pinch bolt. ^ Tighten to 30 Nm (22 ft. lbs.). 11. Position the steering column opening cover and install the 2 screws. 12. CAUTION: The brake pedal must be connected to the brake booster rod, in an at-rest position, before installing the stoplamp switch and the speed control deactivator switch or the switch will be damaged. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake Pedal and Bracket > Page 6019 Install the stoplamp switch. Install the speed control deactivator switch. 13. Repower the supplemental restraint system (SRS). For additional information, refer to Air Bag Systems. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake Pedal and Bracket > Page 6020 Brake Pedal Assy: Service and Repair Brake Pedal Motor Brake Pedal Motor Brake Pedal Motor Removal and Installation 1. Disconnect the accelerator and brake pedal drive cables from the adjustable pedal motor. 2. Disconnect the adjustable pedal motor electrical connector. 3. Remove the 2 adjustable pedal motor screws and then remove the adjustable pedal motor and drive cables as an assembly. ^ To install, tighten to 3 Nm (27 inch lbs.). 4. NOTE: Make sure the brake pedal and the accelerator pedal are in the same position before connecting the drive cable to the adjustable pedals. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps Brake Caliper: Customer Interest Brakes - Rear Brake Rattling Noise Over Bumps TSB 09-22-13 11/16/09 REAR BRAKE RATTLE OVER BUMPS FORD: 2007-2010 Explorer Sport Trac, Explorer MERCURY: 2007-2010 Mountaineer This article supersedes TSB 7-24-6 to update the vehicle model years covered. ISSUE Some 2007-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles may exhibit a rattle noise over bumps from the rear of the vehicle. The noise is due to the rear brakes which do not incorporate an anti-rattle clip. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE To repair the rattle noise perform the following: 1. Remove the rear tires as per the Work Shop Manual (WSM), Section 204-04. 2. Remove the brake caliper assembly from the steering knuckle assembly per WSM, Section 206-04. 3. Support the caliper to prevent damage to the brake line. (Figure 1) 4. Remove the outer and inner brake pad and discard pads. 5. Remove the brake pad slippers from the caliper rails and discard. 6. Clean the caliper rails with a wire brush. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps > Page 6030 7. Place a thin bead of Motorcraft(R) Silicone Gasket and Sealant on center section of the underside of the brake pad slippers. (Figure 2) 8. Install the brake pad slippers on to the caliper rails. The smaller brake pad slipper is attached to the upper caliper rail. The larger brake pad slipper is attached to the lower caliper rail with the anti rattle loop facing away from the rotor. (Figure 3) 9. Clean any excess Motorcraft(R) Silicone Gasket and Sealant off of the slippers. 10. Remove the caliper pin sleeves and rubber boots. 11. Install new pin caliper boots. 12. Place caliper slide grease into the pin sleeve boots. 13. Install caliper slide pin into the rubber boots. 14. Clean any excess grease off of caliper. 15. Install inner and outer brake pads. NOTE THE BRAKE PADS ARE LABELED L FOR LEFT SIDE AND R FOR RIGHT SIDE ON THE STEEL BACKING PLATE. 16. Install brake caliper as per WSM, Section 206-04. 17. Repeat steps 2-16 on the other side. 18. Install the rear tires as per the WSM, Section 204-04. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps > Page 6031 Parts Block 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 092213A 2007-2010 Explorer, 0.8 Hr. Mountaineer, Explorer Sport Trac: Replace The Rear Brake Pads Both Sides Following The Service Procedure (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 2200 07 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps Brake Caliper: All Technical Service Bulletins Brakes - Rear Brake Rattling Noise Over Bumps TSB 09-22-13 11/16/09 REAR BRAKE RATTLE OVER BUMPS FORD: 2007-2010 Explorer Sport Trac, Explorer MERCURY: 2007-2010 Mountaineer This article supersedes TSB 7-24-6 to update the vehicle model years covered. ISSUE Some 2007-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles may exhibit a rattle noise over bumps from the rear of the vehicle. The noise is due to the rear brakes which do not incorporate an anti-rattle clip. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE To repair the rattle noise perform the following: 1. Remove the rear tires as per the Work Shop Manual (WSM), Section 204-04. 2. Remove the brake caliper assembly from the steering knuckle assembly per WSM, Section 206-04. 3. Support the caliper to prevent damage to the brake line. (Figure 1) 4. Remove the outer and inner brake pad and discard pads. 5. Remove the brake pad slippers from the caliper rails and discard. 6. Clean the caliper rails with a wire brush. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps > Page 6037 7. Place a thin bead of Motorcraft(R) Silicone Gasket and Sealant on center section of the underside of the brake pad slippers. (Figure 2) 8. Install the brake pad slippers on to the caliper rails. The smaller brake pad slipper is attached to the upper caliper rail. The larger brake pad slipper is attached to the lower caliper rail with the anti rattle loop facing away from the rotor. (Figure 3) 9. Clean any excess Motorcraft(R) Silicone Gasket and Sealant off of the slippers. 10. Remove the caliper pin sleeves and rubber boots. 11. Install new pin caliper boots. 12. Place caliper slide grease into the pin sleeve boots. 13. Install caliper slide pin into the rubber boots. 14. Clean any excess grease off of caliper. 15. Install inner and outer brake pads. NOTE THE BRAKE PADS ARE LABELED L FOR LEFT SIDE AND R FOR RIGHT SIDE ON THE STEEL BACKING PLATE. 16. Install brake caliper as per WSM, Section 206-04. 17. Repeat steps 2-16 on the other side. 18. Install the rear tires as per the WSM, Section 204-04. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps > Page 6038 Parts Block 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 092213A 2007-2010 Explorer, 0.8 Hr. Mountaineer, Explorer Sport Trac: Replace The Rear Brake Pads Both Sides Following The Service Procedure (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 2200 07 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper removal and installation, Front Brake Caliper: Service and Repair Caliper removal and installation, Front Brake Caliper Material Removal WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in personal injury. 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. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair 2. Remove the brake hose flow bolt and position the brake hose aside. ^ Discard the 2 copper washers. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper removal and installation, Front > Page 6041 ^ Cap the fluid ports. 3. CAUTION: Do not pry in the brake caliper sight hole to retract the pistons as this can damage the pistons and boots. Remove the 2 brake caliper guide pin bolts and the brake caliper. ^ If leaks or damaged boots are found, install a new brake caliper. Installation 1. CAUTION: Tighten the bottom locator pin brake caliper bolt before tightening the top guide pin brake caliper bolt. Position the brake caliper and install the 2 guide pin bolts. ^ Tighten to 72 Nm (53 ft. lbs.). 2. Using 2 new copper washers, position the brake hose and install the brake hose flow bolt. ^ Tighten to 35 Nm (26 ft. lbs.). 3. Bleed the brake caliper. 4. Test the brake system for normal operation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper removal and installation, Front > Page 6042 Brake Caliper: Service and Repair Brake Caliper Anchor Plate, Front Brake Caliper Anchor Plate Removal and Installation 1. Remove the brake pads. 2. Remove and discard the 2 brake caliper anchor plate bolts and remove the brake caliper anchor plate. ^ To install, tighten to 165 Nm (122 ft. lbs.). 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper removal and installation, Front > Page 6043 Brake Caliper: Service and Repair Caliper removal and installation, Rear Brake Caliper Material Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper removal and installation, Front > Page 6044 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair 2. Remove the brake flow bolt and position the brake hose aside. ^ Discard the 2 copper washers. 3. Remove the 2 brake caliper guide pin bolts and remove the brake caliper. 4. Remove the brake pads from the brake caliper. Installation 1. Install the brake pads to the brake caliper. 2. Position the brake caliper and install the 2 guide pin brake caliper bolts. ^ Tighten to 32 Nm (24 ft. lbs.). 3. Using 2 new copper washers, position the brake hose and install the brake hose flow bolt. ^ Tighten to 35 Nm (26 ft. lbs.). 4. Bleed the brake caliper. 5. Test the brake system operation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest for Brake Pad: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps Brake Pad: Customer Interest Brakes - Rear Brake Rattling Noise Over Bumps TSB 09-22-13 11/16/09 REAR BRAKE RATTLE OVER BUMPS FORD: 2007-2010 Explorer Sport Trac, Explorer MERCURY: 2007-2010 Mountaineer This article supersedes TSB 7-24-6 to update the vehicle model years covered. ISSUE Some 2007-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles may exhibit a rattle noise over bumps from the rear of the vehicle. The noise is due to the rear brakes which do not incorporate an anti-rattle clip. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE To repair the rattle noise perform the following: 1. Remove the rear tires as per the Work Shop Manual (WSM), Section 204-04. 2. Remove the brake caliper assembly from the steering knuckle assembly per WSM, Section 206-04. 3. Support the caliper to prevent damage to the brake line. (Figure 1) 4. Remove the outer and inner brake pad and discard pads. 5. Remove the brake pad slippers from the caliper rails and discard. 6. Clean the caliper rails with a wire brush. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest for Brake Pad: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps > Page 6053 7. Place a thin bead of Motorcraft(R) Silicone Gasket and Sealant on center section of the underside of the brake pad slippers. (Figure 2) 8. Install the brake pad slippers on to the caliper rails. The smaller brake pad slipper is attached to the upper caliper rail. The larger brake pad slipper is attached to the lower caliper rail with the anti rattle loop facing away from the rotor. (Figure 3) 9. Clean any excess Motorcraft(R) Silicone Gasket and Sealant off of the slippers. 10. Remove the caliper pin sleeves and rubber boots. 11. Install new pin caliper boots. 12. Place caliper slide grease into the pin sleeve boots. 13. Install caliper slide pin into the rubber boots. 14. Clean any excess grease off of caliper. 15. Install inner and outer brake pads. NOTE THE BRAKE PADS ARE LABELED L FOR LEFT SIDE AND R FOR RIGHT SIDE ON THE STEEL BACKING PLATE. 16. Install brake caliper as per WSM, Section 206-04. 17. Repeat steps 2-16 on the other side. 18. Install the rear tires as per the WSM, Section 204-04. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest for Brake Pad: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps > Page 6054 Parts Block 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 092213A 2007-2010 Explorer, 0.8 Hr. Mountaineer, Explorer Sport Trac: Replace The Rear Brake Pads Both Sides Following The Service Procedure (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 2200 07 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps Brake Pad: All Technical Service Bulletins Brakes - Rear Brake Rattling Noise Over Bumps TSB 09-22-13 11/16/09 REAR BRAKE RATTLE OVER BUMPS FORD: 2007-2010 Explorer Sport Trac, Explorer MERCURY: 2007-2010 Mountaineer This article supersedes TSB 7-24-6 to update the vehicle model years covered. ISSUE Some 2007-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles may exhibit a rattle noise over bumps from the rear of the vehicle. The noise is due to the rear brakes which do not incorporate an anti-rattle clip. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE To repair the rattle noise perform the following: 1. Remove the rear tires as per the Work Shop Manual (WSM), Section 204-04. 2. Remove the brake caliper assembly from the steering knuckle assembly per WSM, Section 206-04. 3. Support the caliper to prevent damage to the brake line. (Figure 1) 4. Remove the outer and inner brake pad and discard pads. 5. Remove the brake pad slippers from the caliper rails and discard. 6. Clean the caliper rails with a wire brush. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps > Page 6060 7. Place a thin bead of Motorcraft(R) Silicone Gasket and Sealant on center section of the underside of the brake pad slippers. (Figure 2) 8. Install the brake pad slippers on to the caliper rails. The smaller brake pad slipper is attached to the upper caliper rail. The larger brake pad slipper is attached to the lower caliper rail with the anti rattle loop facing away from the rotor. (Figure 3) 9. Clean any excess Motorcraft(R) Silicone Gasket and Sealant off of the slippers. 10. Remove the caliper pin sleeves and rubber boots. 11. Install new pin caliper boots. 12. Place caliper slide grease into the pin sleeve boots. 13. Install caliper slide pin into the rubber boots. 14. Clean any excess grease off of caliper. 15. Install inner and outer brake pads. NOTE THE BRAKE PADS ARE LABELED L FOR LEFT SIDE AND R FOR RIGHT SIDE ON THE STEEL BACKING PLATE. 16. Install brake caliper as per WSM, Section 206-04. 17. Repeat steps 2-16 on the other side. 18. Install the rear tires as per the WSM, Section 204-04. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps > Page 6061 Parts Block 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 092213A 2007-2010 Explorer, 0.8 Hr. Mountaineer, Explorer Sport Trac: Replace The Rear Brake Pads Both Sides Following The Service Procedure (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 2200 07 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Page 6062 Brake Pad: Specifications Front Minimum brake pad thickness ........................................................................................................................................................... 3.0 mm (0.118 inch) Maximum brake pad thickness variation (pad-to-pad) ....................................................................................................................... 2.0 mm (0.079 inch) Maximum brake pad taper wear (in any direction) ............................................................................................................................ 3.0 mm (0.118 inch) Rear Minimum brake pad thickness ........................................................................................................................................................... 3.0 mm (0.118 inch) Maximum brake pad thickness variation (pad-to-pad) ....................................................................................................................... 2.0 mm (0.079 inch) Maximum brake pad taper wear (in any direction) ............................................................................................................................ 3.0 mm (0.118 inch) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front Brake Pad: Service and Repair Front Brake Pads Material Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6065 Removal WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in personal injury. 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. 1. Check the brake fluid level in the brake master cylinder reservoir. ^ If required, remove brake fluid until the brake master cylinder reservoir is 1/2 full. 2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair 3. CAUTION: Do not pry in the brake caliper sight hole to retract the pistons as this can damage the pistons and boots. CAUTION: Do not allow the brake caliper to hang from the brake hose or damage to the hose can occur. Remove the 2 brake caliper guide pin bolts and position the brake caliper aside. ^ Support the caliper using mechanic's wire. 4. CAUTION: Install new brake pads if they are worn past the specified thickness above the metal backing plate or rivets. Install new brake pads in complete axle sets. Inspect the brake pads for wear and contamination.. 5. Inspect the brake disc, machine or install a new front brake disc as necessary. 6. Remove the brake pads and clips. ^ Discard the clips. Installation 1. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the pad lining material. Do not install contaminated pads. NOTE: One brake disc pad kit contains the pads and pad clips required for both sides. Install the new brake pad clips and the brake pads. 2. CAUTION: Protect the piston and boots when pushing the caliper piston into the caliper piston bores. Using a suitable tool and a worn brake pad, compress the disc brake caliper pistons into the caliper. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6066 3. Position the brake caliper and install the 2 guide pin bolts. ^ Tighten to 72 Nm (53 ft. lbs.). 4. Fill the brake master cylinder reservoir with clean brake fluid. 5. Test the brakes for normal operation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6067 Brake Pad: Service and Repair Rear Brake pads Material Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6068 Removal WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in personal injury. 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. 1. Check the brake fluid level in the brake master cylinder reservoir. ^ If required, remove the fluid until the brake master cylinder reservoir is half full. 2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair 3. CAUTION: Do not pry in the caliper sight hole to retract the pistons, as this can damage the pistons and boots. CAUTION: Do not allow the brake caliper to hang from the brake hose or damage to the hose can occur. Remove the 2 brake caliper guide pin bolts and position the caliper aside. ^ Support the caliper using mechanic's wire. 4. CAUTION: Install new brake pads if they are worn past the specified thickness above the metal backing plate or rivets. Install new brake pads in complete axle sets. Inspect the brake pads for wear and contamination. 5. Inspect the brake disc, machine or install a new front brake disc as necessary. 6. Remove the 2 brake pads. ^ Discard the brake pad clips. Installation 1. NOTE: One brake disc pad kit contains the linings required for both sides. Install the brake pad clips and brake pads. 2. CAUTION: Protect the piston and boots when pushing the caliper piston into the caliper piston bores. If installing new brake pads, using a suitable tool and a worn brake pad, compress the disc brake caliper pistons into the caliper. 3. Position the brake caliper and install the 2 brake caliper guide pin bolts. ^ Tighten to 32 Nm (24 ft. lbs.). 4. Fill the brake master cylinder reservoir with clean, specified brake fluid. 5. Test the brakes for normal operation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications Brake Rotor/Disc: Specifications Front Brake Disc Front minimum brake disc thickness ................................................................................................................................................. 28.5 mm (1.12 inch) Minimum thickness to machine front disc ......................................................................................................................................... 29.1 mm (1.15 inch) Rear Brake Disc Minimum rear brake disc thickness ................................................................................................................................................... 11.0 mm (0.43 inch) Minimum thickness to machine rear disc ........................................................................................................................................... 11.6 mm (0.45 inch) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures Brake Rotor/Disc: Procedures Brake Disc Machining Material CAUTION: Do not use a bench lathe to machine the brake discs. NOTE: Read the entire operating manual and view the video shipped with the lathe before installing, operating or repairing the lathe. NOTE: If the thickness of the brake disc is less than the minimum thickness to machine specification, install a new brake disc. This will make sure that the brake disc will be above minimum thickness after machining. NOTE: Do not machine new brake discs. NOTE: Lateral runout and disc thickness variation measurements are not required because correct adjustment of the on-vehicle brake lathe will make sure that these dimensions are within specifications. 1. NOTE: It is not necessary to disconnect the brake line from the brake caliper. Position the brake caliper and brake caliper anchor bracket aside. 2. For vehicles with a 2-piece brake disc and hub assembly: 1 Mark the brake disc and the wheel stud for correct indexing during re-assembly. 2 Remove the brake disc from the hub. 3 CAUTION: Do not use an abrasive sanding disc since it will remove paint or other protective finishes from the wheel or metal from the mounting surfaces, adversely affecting corrosion protection and brake disc lateral runout. Remove corrosion from the wheel mounting surface, both disc mounting surfaces and hub mounting surface. 4 Align the match marks and install the brake disc on the hub. 3. Machine the brake disc using an on-vehicle brake lathe. 1 Install the hub adapter and silencer belt if necessary. 2 Install the cutting lathe. 3 If the lathe is not self adjusting, adjust the lathe oscillation using a dial indicator. Total indicated reading (TIR) target is 0.000 mm (0.000 inch), maximum is 0.08 mm (0.003 inch). 4 Center the cutting head, adjust the cutting bits and install the chip deflector. 5 NOTE: The depth of cut should be between 0.10 and 0.20 mm (0.004 and 0.008 inch). Lighter cuts will cause the bit to heat up and wear faster. Heavier cuts will cause poor brake disc surface finish. Machine the brake disc. 6 Remove the lathe and, if installed, the silencer belt. 7 Remove the hub adapter. 4. Remove the metal shavings. 5. For vehicles with a 2-piece brake disc and hub assembly: 1 Remove the brake disc from the hub. 2 Remove metal shavings from the hub, the brake disc mounting surfaces and from the ABS sensors. 3 Apply anti-seize lubricant to the hub mounting surface to prevent corrosion. 4 Align the match marks and install the brake disc on the hub. 6. NOTE: It is not required to install new brake pads if friction material properties are within guidelines. For additional information, refer to Brake Pads. Install the brake caliper and brake caliper anchor bracket. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 6074 Brake Rotor/Disc: Removal and Replacement Disc Removal and Installation, Front Brake Disc Material Removal 1. CAUTION: Do not allow the brake caliper, brake pads and anchor plate assembly to hang from the brake hose or damage to the hose can occur. Remove the 2 brake caliper anchor plate bolts and position the brake caliper, brake pads and anchor plate assembly aside. ^ Support the caliper, brake pads and anchor plate assembly using mechanic's wire. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 6075 2. NOTE: If the brake disc cannot be removed easily, apply rust penetrant on the brake disc-to-hub mating surfaces. Remove the brake disc. Installation 1. Clean any rust or foreign material from brake disc and wheel hub. ^ Use parts cleaner to clean the front brake disc and hub surfaces. 2. Apply a thin coat of anti-seize lubricant to the hub flange. 3. Install the brake disc. 4. Position the brake caliper, brake pads and brake caliper anchor plate assembly and install the 2 brake caliper anchor plate bolts. ^ Tighten to 165 Nm (122 ft. lbs.). Disc Removal and Installation, Rear Brake Disc Material Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 6076 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair 2. CAUTION: Do not pry in the caliper sight hole to retract the pistons, as this can damage the pistons and boots. CAUTION: Do not allow the brake caliper and brake pad assembly to hang from the brake hose or damage to the hose can occur. Remove the 2 brake caliper guide pin bolts, position the caliper and pads aside as an assembly. ^ Support the caliper and brake pad assembly using mechanic's wire. 3. NOTE: If the brake disc binds on the parking brake shoe and lining, remove the adjustment hole knockout panel or access plug and contract the parking brake shoe and lining. NOTE: If the brake disc cannot be removed easily, apply penetrating lock lubricant on the brake disc-to-hub mating surfaces. Remove the brake disc. Installation NOTE: If the adjustment hole knockout panel or access plug was removed, it is necessary to install an access plug to prevent the entry of contaminants. 1. Clean any rust or foreign material from brake disc and wheel hub. ^ Use parts cleaner to clean the front brake disc and hub surfaces. 2. Install the brake disc. 3. Position the brake caliper and brake pad assembly. Install the 2 brake caliper guide pin bolts. ^ Tighten to 32 Nm (24 ft. lbs.). 4. Test the brakes for normal operation. Brake Disc Shield, Front Brake Disc Shield Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 6077 Brake Disc Shield Removal and Installation 1. Remove the brake disc. 2. Remove and discard the 4 brake disc shield bolts. ^ To install, tighten to 8 Nm (71 inch lbs.). 3. Remove the brake disc shield. 4. To install, reverse the removal procedure. Brake Disc Shield, Rear Brake Disc Shield Material Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 6078 Removal 1. Remove the parking brake shoes. 2. Remove the brake disc shield bolts. 3. Cut the shield at the perforations and remove the brake disc shield halves. Installation 1. NOTE: If installing a new brake disc shield, cut the new shield in half at the perforations. Position the brake disc shield halves, and install 2 bolts in each half. ^ Tighten to 8 Nm (71 inch lbs.). 2. Install the parking brake shoes. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Technical Service Bulletins > Customer Interest for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel Brake Bleeding: Customer Interest Brakes - Poor Brake Pedal Feel TSB 09-1-6 01/26/09 IMPROVED BRAKE PEDAL FEEL AND FIRMNESS - BUILT BEFORE 5/31/2008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-2-8 to update the part list and add a production fix date. ISSUE Some 2006-2008 Explorer, Mountaineer, and 2007-2008 Sport Trac vehicles built before 5/31/2008 may experience customer concerns with brake pedal feel or firmness. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Bleed the brake system using the anti-lock brake system (ABS) hydraulic control unit (HCU) bleeding procedure found in Workshop Manual (WSM), Section 206-00. a. If the brake bleeding procedure resolves the concern, do not continue with this TSB and return the vehicle to the customer. b. If the brake bleeding procedure does not resolve the customer concern, replace the brake pedal assembly. 2. Remove brake pedal assembly, Refer to WSM Section 206-06. 3. Install updated brake pedal assembly. Parts Block 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 090106A 2006-2008 0.7 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System (Do Not Use With 2000A) 090106B 2006-2008 1.8 Hrs. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System, Replace The Brake Pedal Assembly (Do Not Use With 2000A, Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Technical Service Bulletins > Customer Interest for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel > Page 6088 13480A, 9818A8) DEALER CODING CONDITION BASIC PART NO. CODE 2455 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Technical Service Bulletins > By Symptom for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel Brake Bleeding: By Symptom Brakes - Poor Brake Pedal Feel TSB 09-1-6 01/26/09 IMPROVED BRAKE PEDAL FEEL AND FIRMNESS - BUILT BEFORE 5/31/2008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-2-8 to update the part list and add a production fix date. ISSUE Some 2006-2008 Explorer, Mountaineer, and 2007-2008 Sport Trac vehicles built before 5/31/2008 may experience customer concerns with brake pedal feel or firmness. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Bleed the brake system using the anti-lock brake system (ABS) hydraulic control unit (HCU) bleeding procedure found in Workshop Manual (WSM), Section 206-00. a. If the brake bleeding procedure resolves the concern, do not continue with this TSB and return the vehicle to the customer. b. If the brake bleeding procedure does not resolve the customer concern, replace the brake pedal assembly. 2. Remove brake pedal assembly, Refer to WSM Section 206-06. 3. Install updated brake pedal assembly. Parts Block 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 090106A 2006-2008 0.7 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System (Do Not Use With 2000A) 090106B 2006-2008 1.8 Hrs. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System, Replace The Brake Pedal Assembly (Do Not Use With 2000A, Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Technical Service Bulletins > By Symptom for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel > Page 6094 13480A, 9818A8) DEALER CODING CONDITION BASIC PART NO. CODE 2455 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel Brake Bleeding: All Technical Service Bulletins Brakes - Poor Brake Pedal Feel TSB 09-1-6 01/26/09 IMPROVED BRAKE PEDAL FEEL AND FIRMNESS - BUILT BEFORE 5/31/2008 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer This article supersedes TSB 08-2-8 to update the part list and add a production fix date. ISSUE Some 2006-2008 Explorer, Mountaineer, and 2007-2008 Sport Trac vehicles built before 5/31/2008 may experience customer concerns with brake pedal feel or firmness. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Bleed the brake system using the anti-lock brake system (ABS) hydraulic control unit (HCU) bleeding procedure found in Workshop Manual (WSM), Section 206-00. a. If the brake bleeding procedure resolves the concern, do not continue with this TSB and return the vehicle to the customer. b. If the brake bleeding procedure does not resolve the customer concern, replace the brake pedal assembly. 2. Remove brake pedal assembly, Refer to WSM Section 206-06. 3. Install updated brake pedal assembly. Parts Block 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 090106A 2006-2008 0.7 Hr. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System (Do Not Use With 2000A) 090106B 2006-2008 1.8 Hrs. Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System, Replace The Brake Pedal Assembly (Do Not Use With 2000A, Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel > Page 6100 13480A, 9818A8) DEALER CODING CONDITION BASIC PART NO. CODE 2455 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake System Bleeding Brake Bleeding: Service and Repair Brake System Bleeding Brake System Bleeding Special Tools Material Master Cylinder Bleeding WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in personal injury. 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 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 new installation, air may get into the system and cause spongy brake pedal feel. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be gravity bled, manually bled or bled using pressure bleeding equipment. 1. NOTE: When a new brake master cylinder has been installed or the system has been emptied or partially emptied, it should be primed to prevent air from getting into the system. Disconnect the brake master cylinder tubes. 2. NOTE: Original equipment tubes are not intended to be used during this procedure. Install the 2 short brake tubes with the ends submerged in the brake master cylinder reservoir and fill the brake master cylinder reservoir with clean, specified brake fluid. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake System Bleeding > Page 6103 3. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes without air bubbles. 4. Remove the 2 short brake tubes and install the 2 master cylinder brake tubes. 5. Bleed each brake tube at the brake master cylinder as follows: 1 Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 2 Loosen the rear brake tube fitting until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the brake tube fitting. 3 Repeat this operation until clear, bubble-free fluid comes out. 4 Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front brake tube. 6. While the assistant maintains pressure on the brake pedal, tighten the master cylinder brake tubes. ^ Tighten to 18 Nm (13 ft. lbs.). Brake Caliper Bleeding NOTE: It is not necessary to bleed the entire brake system. It is possible to bleed only the opened part of the system. 1. Connect one end of a clear flexible hose to the bleeder screw. Submerge the other end in a container partially filled with clean, specified brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Open the caliper bleeder screw until brake fluid flows into the container. 4. When fluid stops flowing, close the bleeder screw. ^ Tighten to 10 Nm (89 inch lbs.) for the front brake bleeder screw and 22 Nm (16 ft. lbs.) for the rear brake bleeder screw. 5. Repeat the previous 3 steps until there are no air bubbles in the brake fluid. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake System Bleeding > Page 6104 Brake Bleeding: Service and Repair Anti-Lock Brake System (ABS) Hydraulic Control Unit (HCU) Bleeding Anti-Lock Brake System (ABS) Hydraulic Control Unit (HCU) Bleeding NOTE: This procedure is required only when a new HCU is installed. 1. Connect the scan tool and follow the ABS bleed instructions. 2. Use the caliper bleed procedure to bleed the system. Begin at the RH rear caliper. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps Brake Caliper: Customer Interest Brakes - Rear Brake Rattling Noise Over Bumps TSB 09-22-13 11/16/09 REAR BRAKE RATTLE OVER BUMPS FORD: 2007-2010 Explorer Sport Trac, Explorer MERCURY: 2007-2010 Mountaineer This article supersedes TSB 7-24-6 to update the vehicle model years covered. ISSUE Some 2007-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles may exhibit a rattle noise over bumps from the rear of the vehicle. The noise is due to the rear brakes which do not incorporate an anti-rattle clip. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE To repair the rattle noise perform the following: 1. Remove the rear tires as per the Work Shop Manual (WSM), Section 204-04. 2. Remove the brake caliper assembly from the steering knuckle assembly per WSM, Section 206-04. 3. Support the caliper to prevent damage to the brake line. (Figure 1) 4. Remove the outer and inner brake pad and discard pads. 5. Remove the brake pad slippers from the caliper rails and discard. 6. Clean the caliper rails with a wire brush. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps > Page 6113 7. Place a thin bead of Motorcraft(R) Silicone Gasket and Sealant on center section of the underside of the brake pad slippers. (Figure 2) 8. Install the brake pad slippers on to the caliper rails. The smaller brake pad slipper is attached to the upper caliper rail. The larger brake pad slipper is attached to the lower caliper rail with the anti rattle loop facing away from the rotor. (Figure 3) 9. Clean any excess Motorcraft(R) Silicone Gasket and Sealant off of the slippers. 10. Remove the caliper pin sleeves and rubber boots. 11. Install new pin caliper boots. 12. Place caliper slide grease into the pin sleeve boots. 13. Install caliper slide pin into the rubber boots. 14. Clean any excess grease off of caliper. 15. Install inner and outer brake pads. NOTE THE BRAKE PADS ARE LABELED L FOR LEFT SIDE AND R FOR RIGHT SIDE ON THE STEEL BACKING PLATE. 16. Install brake caliper as per WSM, Section 206-04. 17. Repeat steps 2-16 on the other side. 18. Install the rear tires as per the WSM, Section 204-04. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps > Page 6114 Parts Block 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 092213A 2007-2010 Explorer, 0.8 Hr. Mountaineer, Explorer Sport Trac: Replace The Rear Brake Pads Both Sides Following The Service Procedure (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 2200 07 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps Brake Caliper: All Technical Service Bulletins Brakes - Rear Brake Rattling Noise Over Bumps TSB 09-22-13 11/16/09 REAR BRAKE RATTLE OVER BUMPS FORD: 2007-2010 Explorer Sport Trac, Explorer MERCURY: 2007-2010 Mountaineer This article supersedes TSB 7-24-6 to update the vehicle model years covered. ISSUE Some 2007-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles may exhibit a rattle noise over bumps from the rear of the vehicle. The noise is due to the rear brakes which do not incorporate an anti-rattle clip. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE To repair the rattle noise perform the following: 1. Remove the rear tires as per the Work Shop Manual (WSM), Section 204-04. 2. Remove the brake caliper assembly from the steering knuckle assembly per WSM, Section 206-04. 3. Support the caliper to prevent damage to the brake line. (Figure 1) 4. Remove the outer and inner brake pad and discard pads. 5. Remove the brake pad slippers from the caliper rails and discard. 6. Clean the caliper rails with a wire brush. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps > Page 6120 7. Place a thin bead of Motorcraft(R) Silicone Gasket and Sealant on center section of the underside of the brake pad slippers. (Figure 2) 8. Install the brake pad slippers on to the caliper rails. The smaller brake pad slipper is attached to the upper caliper rail. The larger brake pad slipper is attached to the lower caliper rail with the anti rattle loop facing away from the rotor. (Figure 3) 9. Clean any excess Motorcraft(R) Silicone Gasket and Sealant off of the slippers. 10. Remove the caliper pin sleeves and rubber boots. 11. Install new pin caliper boots. 12. Place caliper slide grease into the pin sleeve boots. 13. Install caliper slide pin into the rubber boots. 14. Clean any excess grease off of caliper. 15. Install inner and outer brake pads. NOTE THE BRAKE PADS ARE LABELED L FOR LEFT SIDE AND R FOR RIGHT SIDE ON THE STEEL BACKING PLATE. 16. Install brake caliper as per WSM, Section 206-04. 17. Repeat steps 2-16 on the other side. 18. Install the rear tires as per the WSM, Section 204-04. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps > Page 6121 Parts Block 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 092213A 2007-2010 Explorer, 0.8 Hr. Mountaineer, Explorer Sport Trac: Replace The Rear Brake Pads Both Sides Following The Service Procedure (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 2200 07 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper removal and installation, Front Brake Caliper: Service and Repair Caliper removal and installation, Front Brake Caliper Material Removal WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in personal injury. 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. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair 2. Remove the brake hose flow bolt and position the brake hose aside. ^ Discard the 2 copper washers. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper removal and installation, Front > Page 6124 ^ Cap the fluid ports. 3. CAUTION: Do not pry in the brake caliper sight hole to retract the pistons as this can damage the pistons and boots. Remove the 2 brake caliper guide pin bolts and the brake caliper. ^ If leaks or damaged boots are found, install a new brake caliper. Installation 1. CAUTION: Tighten the bottom locator pin brake caliper bolt before tightening the top guide pin brake caliper bolt. Position the brake caliper and install the 2 guide pin bolts. ^ Tighten to 72 Nm (53 ft. lbs.). 2. Using 2 new copper washers, position the brake hose and install the brake hose flow bolt. ^ Tighten to 35 Nm (26 ft. lbs.). 3. Bleed the brake caliper. 4. Test the brake system for normal operation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper removal and installation, Front > Page 6125 Brake Caliper: Service and Repair Brake Caliper Anchor Plate, Front Brake Caliper Anchor Plate Removal and Installation 1. Remove the brake pads. 2. Remove and discard the 2 brake caliper anchor plate bolts and remove the brake caliper anchor plate. ^ To install, tighten to 165 Nm (122 ft. lbs.). 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper removal and installation, Front > Page 6126 Brake Caliper: Service and Repair Caliper removal and installation, Rear Brake Caliper Material Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper removal and installation, Front > Page 6127 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair 2. Remove the brake flow bolt and position the brake hose aside. ^ Discard the 2 copper washers. 3. Remove the 2 brake caliper guide pin bolts and remove the brake caliper. 4. Remove the brake pads from the brake caliper. Installation 1. Install the brake pads to the brake caliper. 2. Position the brake caliper and install the 2 guide pin brake caliper bolts. ^ Tighten to 32 Nm (24 ft. lbs.). 3. Using 2 new copper washers, position the brake hose and install the brake hose flow bolt. ^ Tighten to 35 Nm (26 ft. lbs.). 4. Bleed the brake caliper. 5. Test the brake system operation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid Ford Part Number ................................................................................................................................ ................................................... PM-1 or PM-1-C Ford Specification ...................................................................................................................................................... ESA-M6C25-A or WSS-M6C62-A Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations View 151-1 (Engine Compartment - 4.0L, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 6134 C124 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Procedures Hydraulic Control Assembly - Antilock Brakes: Procedures Anti-Lock Brake System (ABS) Hydraulic Control Unit (HCU) Bleeding NOTE: This procedure is required only when a new HCU is installed. 1. Connect the scan tool and follow the ABS bleed instructions. 2. Use the caliper bleed procedure to bleed the system. Begin at the RH rear caliper. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Procedures > Page 6139 Hydraulic Control Assembly - Antilock Brakes: Removal and Replacement Hydraulic Control Unit (HCU) Material Removal and Installation WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in personal injury. 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Procedures > Page 6140 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair 2. Remove the battery tray. 3. Disconnect the anti-lock brake system (ABS) module electrical connector. 4. NOTE: The brake tubes must be installed in the same location as removed. Remove the 2 brake tube-to-hydraulic control unit (HCU) fittings and position the brake tubes aside. ^ To install, tighten to 23 Nm (17 ft. lbs.). 5. NOTE: The brake tubes must be installed in the same location as removed. Remove the 4 brake tube-to-HCU extension tube fittings. ^ To install, tighten to 18 Nm (13 ft. lbs.). 6. Remove the 3 HCU bracket-to-frame nuts. ^ To install, tighten to 23 Nm (17 ft. lbs.). 7. Remove the HCU assembly. 8. NOTE: The brake tubes must be installed in the same location as removed. Remove the 4 HCU extension tube-to-HCU fittings. ^ To install, tighten to 18 Nm (13 ft. lbs.). 9. Remove the 2 HCU bracket-to-HCU extension tube retainer nuts and the extension tube retainer assembly. ^ To install, tighten to 9 Nm (80 inch lbs.). 10. Remove the bracket-to-HCU bolts and the HCU bracket. ^ To install, tighten to 9 Nm (80 inch lbs.). 11. To install, reverse the removal procedure. ^ Bleed the brake system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Brake Master Cylinder Bypass Condition Brake Master Cylinder: Testing and Inspection Brake Master Cylinder Bypass Condition Brake Master Cylinder Bypass Condition 1. Disconnect the brake tubes 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 a new master cylinder must be installed. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Brake Master Cylinder Bypass Condition > Page 6145 Brake Master Cylinder: Testing and Inspection Compensator Port Compensator Port 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 tubes 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 application or release of the brake pedal is normal and shows that the compensating ports are not plugged. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Page 6146 Brake Master Cylinder: Service and Repair Brake Master Cylinder Material Removal and Installation WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in personal injury. 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Page 6147 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Use a suitable suction device to drain the brake master cylinder reservoir. 3. Disconnect the brake fluid level warning switch electrical connector. 4. Disconnect the 2 brake tube fittings from the brake master cylinder. ^ To install, tighten to 18 Nm (13 ft. lbs.). 5. Remove the 2 nuts, the brake master cylinder and the square cut seal. ^ To install, tighten to 25 Nm (18 ft. lbs.). 6. NOTE: Make sure that the square cut seal is properly installed or incorrect brake pedal feel can occur. To install, reverse the removal procedure. ^ Bleed the brake system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Parking Brake Cable Tension Release Parking Brake Cable: Service and Repair Parking Brake Cable Tension Release Parking Brake Cable Tension Release 1. Remove the LH cowl side trim panel. 2. With the help of an assistant, release the parking brake cable tension by pulling down on the intermediate cable at the cable-to-cable connector clip until the parking brake control sector rotates to its stop and a 4 mm (0.15 inch) x 150 mm (5.9 inch) retainer pin can be inserted. 3. NOTE: Make sure the cable-to-cable connector clip is connected to the front and rear cable before removing the brake control retaining pin, and the cable tension is reloaded slowly. Disconnect the cable-to-cable connector clip. 4. To reload the tension on the parking brake cable, follow the release procedure in reverse. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Parking Brake Cable Tension Release > Page 6153 Parking Brake Cable: Service and Repair Parking Brake Cable - Rear, LH Parking Brake Cable - Rear, LH Paring Brake Cable - Rear, LH Removal and Installation 1. Release the parking brake cable tension. 2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair 3. Remove the 2 wire form bolts. ^ To install, tighten to 15 Nm (11 ft. lbs.). 4. Disconnect the intermediate cable from the LH rear cable at the cable equalizer. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Parking Brake Cable Tension Release > Page 6154 5. Disconnect the front of the LH rear cable conduit at the frame bracket. 6. Disconnect the LH parking brake cable from the parking brake lever and remove the cable. 7. To install, reverse the removal procedure. ^ Test the parking brake system for correct operation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Parking Brake Cable Tension Release > Page 6155 Parking Brake Cable: Service and Repair Parking Brake Cable - Rear, RH Parking Brake Cable - Rear, RH Parking Brake Cable - Rear, RH Removal and Installation 1. Release the parking brake cable tension. 2. With the vehicle in NEUTRAL position it on a hoist. For additional information, refer to Maintenance/Service and Repair 3. Remove the 2 wire form bolts. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Parking Brake Cable Tension Release > Page 6156 ^ To install, tighten to 15 Nm (11 ft. lbs.). 4. Remove the 2 parking brake cable bracket-to-crossmember bolts. ^ To install, tighten to 15 Nm (11 ft. lbs.). 5. Disconnect the intermediate parking brake cable from the RH rear parking brake cable at the parking brake cable equalizer. 6. Disconnect the front of the RH parking brake cable conduit at the frame bracket. 7. Disconnect the RH parking brake cable from the parking brake lever and remove the parking brake cable. 8. To install, reverse the removal procedure. ^ Test the parking brake system for correct operation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Parking Brake Cable Tension Release > Page 6157 Parking Brake Cable: Service and Repair Parking Brake Cable - Front Parking Brake Cable - Front Parking Brake Cable - Front (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Parking Brake Cable Tension Release > Page 6158 Parking Brake Cable - Front (Part 2) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair 2. Remove the screw and the hood latch release handle. 3. Remove the pin-type retainer and the LH A-pillar lower trim panel. 4. Remove the hood latch release cable assembly screw and position the release cable assembly aside. 5. Release the tension on the parking brake cable. For additional information, refer to Parking Brake Cable Tension Release. 6. Remove the 2 screws and the instrument panel steering column cover. 7. Remove the 2 parking brake release handle bolts from the bracket. ^ To install, tighten to 3 Nm (27 inch lbs.). 8. Disconnect the parking brake switch electrical connector. 9. Remove the wiring harness bracket screw and position the harness and bracket aside. 10. Remove the 3 bolts from the parking brake control. ^ To install, tighten to 20 Nm (15 ft. lbs.). 11. Position the carpet aside. 12. NOTE: The parking brake control take-up spool tab may need to be bent aside to allow the cable to be removed. Disconnect the front parking brake cables from the parking brake control. 13. Disconnect the front parking brake cable conduit from the parking brake control. 14. Disconnect the front parking brake cable from the bracket and remove the cable. 15. To install, reverse the removal procedure. ^ Test the parking brake system for correct operation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Parking Brake Cable Tension Release > Page 6159 Parking Brake Cable: Service and Repair Parking Brake Cable - Intermediate Parking Brake Cable - Intermediate NOTE: The equalizer is integral to the intermediate cable. Note: The Equalizer Is Integral To The Intermediate Cable. Removal and Installation 1. Release the tension on the parking brake cable. For additional information, refer to Parking Brake Cable Tension Release. 2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair 3. Disconnect the intermediate parking brake cable from the front cable at the cable connector clip. 4. Disconnect the LH and RH rear parking brake cables from the intermediate parking brake cable at the equalizer. 5. Remove the intermediate parking brake cable. 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Service and Repair Parking Brake Control: Service and Repair Parking Brake Control Parking Brake Control (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Service and Repair > Page 6163 Parking Brake Control (Part 2) Removal and Installation 1. Remove the screw and the hood latch release handle. 2. Remove the pin-type retainer and the LH A-pillar lower trim panel. 3. Remove the hood latch release cable assembly screw and position the release cable assembly aside. 4. Release the tension on the parking brake cable. 5. Remove the 2 screws and the instrument panel steering column cover. 6. Remove the 2 parking brake release handle bolts from the bracket. ^ To install, tighten to 3 Nm (27 inch lbs.). 7. Disconnect the parking brake switch electrical connector. 8. Remove the wiring harness bracket screw and position the harness and bracket aside. 9. Remove the 3 bolts from the parking brake control. ^ To install, tighten to 20 Nm (15 ft. lbs.). 10. Position the carpet aside and position the cable conduit grommet up through the floor. 11. NOTE: The parking brake control take-up spool tab may need to be bent aside to allow the cable to be removed. Disconnect the front parking brake cable and conduit from the parking brake control. 12. Remove the parking brake control from the vehicle. 13. To install, reverse the removal procedure. ^ Test the parking brake system for correct operation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Pedal: > 07-17-4 > Sep > 07 > Brakes Parking Brake Release Handle Broken Parking Brake Pedal: Customer Interest Brakes - Parking Brake Release Handle Broken TSB 07-17-4 09/03/07 PARKING BRAKE RELEASE HANDLE BREAKS - VEHICLES BUILT BEFORE 1211/2006 FORD: 2006-2007 Explorer 2007 Explorer Sport Trac MERCURY: 2006-2007 Mountaineer ISSUE Some 2006-2007 Explorer 4dr, Mountaineer, and 2007 Explorer Sport Trac vehicles built prior to 12/1/2006 may exhibit separation of parking brake release handle. The issue has no effect on brake or parking brake performance. ACTION Follow the Service Procedure steps to correct the condition by replacing the handle. SERVICE PROCEDURE Follow Workshop Manual (WSM), Section 206-05 to replace the parking brake release handle. NOTE USE CARE WITH THE WIRE HARNESSES ROUTED IN CLOSE PROXIMITY TO THE BRACKET. DO NOT INSTALL BRACKET IN A MANNER THAT WOULD ALLOW THE HARNESS TO BE PINCHED, TRAPPED, OR SMASHED. 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 071704A 2006-2007 0.9 Hr. Explorer/Mountaineer, 2007 Explorer Sport Trac Built Before 12/01/2006: Replace The Parking Brake Control (Do Not Use With 2780A) DEALER CODING CONDITION BASIC PART NO. CODE 2780 01 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Pedal: > 07-17-4 > Sep > 07 > Brakes - Parking Brake Release Handle Broken Parking Brake Pedal: All Technical Service Bulletins Brakes - Parking Brake Release Handle Broken TSB 07-17-4 09/03/07 PARKING BRAKE RELEASE HANDLE BREAKS - VEHICLES BUILT BEFORE 1211/2006 FORD: 2006-2007 Explorer 2007 Explorer Sport Trac MERCURY: 2006-2007 Mountaineer ISSUE Some 2006-2007 Explorer 4dr, Mountaineer, and 2007 Explorer Sport Trac vehicles built prior to 12/1/2006 may exhibit separation of parking brake release handle. The issue has no effect on brake or parking brake performance. ACTION Follow the Service Procedure steps to correct the condition by replacing the handle. SERVICE PROCEDURE Follow Workshop Manual (WSM), Section 206-05 to replace the parking brake release handle. NOTE USE CARE WITH THE WIRE HARNESSES ROUTED IN CLOSE PROXIMITY TO THE BRACKET. DO NOT INSTALL BRACKET IN A MANNER THAT WOULD ALLOW THE HARNESS TO BE PINCHED, TRAPPED, OR SMASHED. 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 071704A 2006-2007 0.9 Hr. Explorer/Mountaineer, 2007 Explorer Sport Trac Built Before 12/01/2006: Replace The Parking Brake Control (Do Not Use With 2780A) DEALER CODING CONDITION BASIC PART NO. CODE 2780 01 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair Parking Brake Shoe: Service and Repair Parking Brake Shoes Special Tools Removal NOTE: A parking brake shoe kit contains the linings required for both the LH and RH side. 1. NOTE: Make sure the parking brake control is fully released. Release the tension on the parking brake cable. 2. Remove the rear brake disc. 3. Remove the parking brake shoe adjusting screw. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 6180 4. Remove the parking brake shoe adjusting screw spring. 5. Remove the 2 parking brake shoe hold-down springs and pins. 6. Remove the parking brake shoe retracting spring and the parking brake shoes. Installation 1. Position the parking brake shoes and attach the retracting spring. 2. Install the 2 parking brake shoe hold-down pins and springs. 3. Install the parking brake shoe adjusting screw spring. 4. NOTE: Completely retract the parking brake adjusting screw before installation. Install the brake shoe adjusting screw. 5. Using the special tool, measure the inside diameter of the parking brake drum. 6. Adjust the parking brake shoe clearance of 0.54 mm (0.021 inch) less than the inside diameter of the parking brake drum. ^ Make sure that the parking brake shoes are correctly centered and measure across the center point of the shoes. ^ Rotate the parking brake shoe adjuster wheel to achieve the correct parking brake shoe-to-brake disc clearance. 7. Install the rear brake disc. 8. Reload the tension on the parking brake cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations View 151-13 (Left Front) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 6184 C2015 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor > Component Information > Locations View 151-2 (Engine Compartment - 4.0L, (2 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor > Component Information > Locations > Page 6189 C149 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Torque Specifications Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 6193 Vacuum Brake Booster: Description and Operation Brake Booster The vacuum type power brake booster: ^ is a dual diaphragm, vacuum assisted power brake booster. ^ reduces brake pedal force and travel distance. ^ is located on the LH side of the bulkhead in the engine compartment, between the brake pedal and the brake master cylinder. ^ is divided into separate chambers by the diaphragms. ^ 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. Hose and Check Valve 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. ^ traps engine vacuum in the power brake booster when in the CLOSED position. ^ retains vacuum to provide 2-3 power-assisted brake applications with the engine off. Active Brake Booster With Stability Assist The active brake booster functions like a conventional brake booster with the added feature that it can be actuated electrically by the stability assist module. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 6194 Vacuum Brake Booster: Testing and Inspection Brake Booster 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. 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 brake booster system is not functioning. Continue with the following steps. 4. Remove the vacuum booster hose from the 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 manifold vacuum is available to the brake booster, connect the vacuum booster hose to the brake booster check valve and repeat Steps 2 and 3. 5. If no downward movement of the brake pedal is felt, install a new 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 N (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 brake booster check valve and retest. If the brake pedal feels spongy, bleed the hydraulic system to remove air. For additional information, refer to Brake System Bleeding. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 6195 Vacuum Brake Booster: Service and Repair Brake Booster Brake Booster Removal and Installation 1. CAUTION: The brake booster check valve must be disconnected from the brake booster prior to removing the master cylinder or the master cylinder seal may be drawn into the brake booster. Disconnect the brake booster check valve from the brake booster to deplete the residual vacuum in the brake booster. 2. Remove the brake master cylinder. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 6196 3. NOTE: When the repair is complete, make sure that the brake booster solenoid electrical connector is connected, or use of the vehicle with key-on or vehicle running will result in diagnostic trouble codes (DTCs) being set. Disconnect the brake booster solenoid electrical connector. 4. NOTE: The booster push rod clevis locking pin is a one-time use only part. Anytime the booster push rod clevis locking pin is removed a new booster push rod clevis locking pin should be used. Remove the booster push rod clevis locking pin and discard. 5. Disconnect the brake booster rod from the brake pedal and position aside. 6. NOTE: Use new nuts when installing the brake booster. Remove the 4 brake booster nuts and the booster. ^ To install, tighten to 22 Nm (16 ft. lbs.). 7. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Testing and Inspection Vacuum Brake Booster Check Valve: Testing and Inspection Check Valve The function of the brake booster check valve is to allow manifold vacuum to enter the brake booster and prevent the escape of vacuum if manifold vacuum is lost during sustained full throttle operation. To test the function of the 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 brake booster check valve. Do not remove the brake booster check valve from the brake booster There should be enough vacuum retained in the brake booster for at least one more power-assisted brake operation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Locations View 151-11 (behind Dash Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Locations > Page 6204 C239 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations View 151-2 (Engine Compartment - 4.0L, (2 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 6209 C155 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 6210 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System (ABS) Module Material Removal and Installation WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in personal injury. 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: Electronic modules are sensitive to electrical charges. The ABS module can be damaged if exposed to these charges. NOTE: When installing a new ABS module, it must be configured (using vehicle as-built data) and calibrated. Follow the scan tool directions for the calibration procedures. For module configuration, refer to Information Bus. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 6211 1. Remove the hydraulic control unit (HCU). 2. CAUTION: Make sure that the ABS module is properly seated to the HCU and that the torque of the ABS module screws is correct, or damage to the components can occur. Remove the 4 screws and the ABS module. ^ To install, tighten to 2 Nm (18 inch lbs.). 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations View 151-11 (behind Dash Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations > Page 6215 C239 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Service and Repair ABS Sensor Block: Service and Repair Stability Control Sensor Cluster Stability Control Sensor Cluster Removal and Installation NOTE: When installing a new stability control sensor cluster, the anti-lock brake system (ABS) module must be calibrated. Follow the scan tool directions for the calibration procedures. 1. Remove the pin-type retainer and the driver side floor console finish panel. 2. Remove the 2 bolts, 2 nuts and the LH instrument panel brace. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Service and Repair > Page 6220 ^ To install, tighten to 9 Nm (80 inch lbs.). 3. Remove the 2 screws and LH heater duct. 4. Disconnect the stability control sensor cluster electrical connector. 5. Remove the stability control sensor cluster electrical harness retainers and position aside. 6. Remove the 2 stability control sensor cluster bracket nuts and the stability control sensor cluster. ^ To install, tighten to 7 Nm (62 inch lbs.). 7. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations View 151-2 (Engine Compartment - 4.0L, (2 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations > Page 6224 C149 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations View 151-1 (Engine Compartment - 4.0L, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 6228 C124 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Service and Repair Lateral Accelerometer: Service and Repair Stability Control Sensor Cluster Stability Control Sensor Cluster Removal and Installation NOTE: When installing a new stability control sensor cluster, the anti-lock brake system (ABS) module must be calibrated. Follow the scan tool directions for the calibration procedures. 1. Remove the pin-type retainer and the driver side floor console finish panel. 2. Remove the 2 bolts, 2 nuts and the LH instrument panel brace. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Service and Repair > Page 6232 ^ To install, tighten to 9 Nm (80 inch lbs.). 3. Remove the 2 screws and LH heater duct. 4. Disconnect the stability control sensor cluster electrical connector. 5. Remove the stability control sensor cluster electrical harness retainers and position aside. 6. Remove the 2 stability control sensor cluster bracket nuts and the stability control sensor cluster. ^ To install, tighten to 7 Nm (62 inch lbs.). 7. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations View 151-13 (Left Front) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 6236 C2015 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Service and Repair Steering Angle Sensor: Service and Repair Steering Wheel Rotation Sensor Steering Wheel Rotation Sensor Removal and Installation 1. Remove the 3 lower steering column cover bolts and the lower steering column cover. 2. Remove the upper steering column cover. 3. Disconnect the steering wheel rotation sensor electrical connector. 4. Remove the 2 bolts and the steering wheel rotation sensor. 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations View 151-11 (behind Dash Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 6243 C280 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 6244 Traction Control Switch: Service and Repair Stability/Traction Control Switch Removal and Installation 1. Remove the 2 floor console center finish panel screws and the floor console center finish panel. ^ To install, tighten to 9 Nm (80 inch lbs.). 2. Apply the parking brake. 3. Move the gear selector lever to the D1 position. 4. Position the instrument panel center finish panel away from the instrument panel. 5. Disconnect the stability traction control switch electrical connector and remove the stability traction control switch from the instrument panel Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 6245 center finish panel. 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left/Right Front View 151-2 (Engine Compartment - 4.0L, (2 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left/Right Front > Page 6250 View 151-15 (Left Rear, (1 0f 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left/Right Front > Page 6251 View 151-17 (Right Rear, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front C150 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 6254 C440 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 6255 C160 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front > Page 6256 C426 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Front Wheel Speed Sensor - Front Wheel Speed Sensor - Front Removal and Installation 1. Remove the front brake disc. 2. Disconnect the wheel speed sensor electrical connector. 3. Remove the wheel speed sensor harness bolt. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 6259 4. Remove the wheel speed sensor harness pin-type retainers. 5. Remove the wheel speed sensor bolt. ^ To install, tighten to 17 Nm (13 ft. lbs.). 6. Remove the wheel speed sensor and the harness. 7. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 6260 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Rear Wheel Speed Sensor - Rear Wheel Speed Sensor - Rear Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair 2. Disconnect the wheel speed sensor electrical connector. 3. Disconnect the wheel speed harness from the retainers. 4. Remove the wheel speed sensor bolt and the wheel speed sensor. ^ To install, tighten to 8 Nm (71 inch lbs.). 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations View 151-12 (Center Console) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 6264 C3073 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 6265 Yaw Rate Sensor: Service and Repair Stability Control Sensor Cluster Stability Control Sensor Cluster Removal and Installation NOTE: When installing a new stability control sensor cluster, the anti-lock brake system (ABS) module must be calibrated. Follow the scan tool directions for the calibration procedures. 1. Remove the pin-type retainer and the driver side floor console finish panel. 2. Remove the 2 bolts, 2 nuts and the LH instrument panel brace. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 6266 ^ To install, tighten to 9 Nm (80 inch lbs.). 3. Remove the 2 screws and LH heater duct. 4. Disconnect the stability control sensor cluster electrical connector. 5. Remove the stability control sensor cluster electrical harness retainers and position aside. 6. Remove the 2 stability control sensor cluster bracket nuts and the stability control sensor cluster. ^ To install, tighten to 7 Nm (62 inch lbs.). 7. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER Removal and Installation NOTE: - When any new lock cylinder is installed, the driver door and ignition lock cylinders should be installed as a set. This eliminates carrying an extra key which fits only 1 lock. If a new key is used, 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. With the ignition switch in the ON position, press the locking pin with a suitable tool and remove the ignition lock cylinder. 2. To install, reverse the removal procedure. - Lubricate the ignition lock cylinder during installation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement Technical Service Bulletin # 09B11 Date: 100115 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on January 15, 2010. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 6281 FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website on January 15, 2010. Owner names and addresses will be available on January 31, 2010. 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 program 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 field service action. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected customers whose vehicles are not on your VIN list 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 service action. 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 service action 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 ^ Ford Motor Company will only refund owner-paid repairs covered by this program if the repair was performed before the date of the Owner Notification Letter. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ If a "stuck in park" event occurs, customers can override the brake shift interlock with information located in the Owner Guide. The 09B11 Owner Letter provides directions to locate the override information and includes a representative brake shift interlock owner guide attachment. There should be no emergency repair refunds after the customer mailings are complete. ^ Refunds will only be provided for the cost associated with the diagnosis and replacement of the transmission gearshift lever due to a "stuck in park" concern. ^ 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. ^ The refund period for repairs performed prior to the date of the Owner Notification Letter will expire on July 31, 2010. ^ Refund Claiming Information (submit on separate repair line). - Program Code: 09B11 - 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 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 6282 ^ 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 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. ^ Refer to ACESII manual for claims preparation and submission information. ^ PROGRAM TERMS: This program will be in effect until January 31, 2011 regardless of mileage. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this recall is 50415. DEALER PRICE For latest prices, 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 In some of the affected vehicles, the transmission gearshift lever may not move out of the park position even when the brake pedal is depressed. This "stuck in park" condition can develop due to silicon dioxide contamination building up on the contacts of the park detect switch located on the transmission gearshift lever. SERVICE PROCEDURE 1. Remove the front floor console. Refer to the appropriate WSM Section 501-12 Console - Front. 2. NOTICE: Electronic modules are sensitive to static electrical charges If the new circuit board is exposed to these charges, damage may result The circuit board should be handled by the plastic connector(s) and avoid touching any of the metal surfaces. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 6283 Disconnect the three electrical connectors from the white circuit board that is located on the lower RH section of the transmission gearshift lever See Figure 1. 3. Remove the circuit board case from the RH side of the transmission gearshift lever by releasing the two retainer clips See Figure 2. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 6284 4. Replace the circuit board See Figure 3. ^ Separate the upper circuit board case cover from the lower case containing the circuit board. ^ Remove and discard the circuit board Install the new circuit board. Snap the upper circuit board case cover and the lower case back together. 5. To reinstall the circuit board case, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 6285 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 6286 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 6287 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement Technical Service Bulletin # 09B11 Date: 100115 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on January 15, 2010. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 6293 FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website on January 15, 2010. Owner names and addresses will be available on January 31, 2010. 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 program 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 field service action. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected customers whose vehicles are not on your VIN list 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 service action. 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 service action 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 ^ Ford Motor Company will only refund owner-paid repairs covered by this program if the repair was performed before the date of the Owner Notification Letter. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ If a "stuck in park" event occurs, customers can override the brake shift interlock with information located in the Owner Guide. The 09B11 Owner Letter provides directions to locate the override information and includes a representative brake shift interlock owner guide attachment. There should be no emergency repair refunds after the customer mailings are complete. ^ Refunds will only be provided for the cost associated with the diagnosis and replacement of the transmission gearshift lever due to a "stuck in park" concern. ^ 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. ^ The refund period for repairs performed prior to the date of the Owner Notification Letter will expire on July 31, 2010. ^ Refund Claiming Information (submit on separate repair line). - Program Code: 09B11 - 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 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 6294 ^ 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 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. ^ Refer to ACESII manual for claims preparation and submission information. ^ PROGRAM TERMS: This program will be in effect until January 31, 2011 regardless of mileage. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this recall is 50415. DEALER PRICE For latest prices, 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 In some of the affected vehicles, the transmission gearshift lever may not move out of the park position even when the brake pedal is depressed. This "stuck in park" condition can develop due to silicon dioxide contamination building up on the contacts of the park detect switch located on the transmission gearshift lever. SERVICE PROCEDURE 1. Remove the front floor console. Refer to the appropriate WSM Section 501-12 Console - Front. 2. NOTICE: Electronic modules are sensitive to static electrical charges If the new circuit board is exposed to these charges, damage may result The circuit board should be handled by the plastic connector(s) and avoid touching any of the metal surfaces. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 6295 Disconnect the three electrical connectors from the white circuit board that is located on the lower RH section of the transmission gearshift lever See Figure 1. 3. Remove the circuit board case from the RH side of the transmission gearshift lever by releasing the two retainer clips See Figure 2. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 6296 4. Replace the circuit board See Figure 3. ^ Separate the upper circuit board case cover from the lower case containing the circuit board. ^ Remove and discard the circuit board Install the new circuit board. Snap the upper circuit board case cover and the lower case back together. 5. To reinstall the circuit board case, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 6297 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 6298 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 6299 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Page 6300 View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Page 6301 C167 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Technical Service Bulletins > Page 6302 Neutral Safety Switch: Testing and Inspection Digital Transmission Range (TR) Sensor Diagnosis Chart Digital Transmission Range (TR) Sensor Diagnosis Chart Wiggle Test Information for Open/Shorts ^ TR4, TR3A, TR2 and TR1 are all closed in PARK. PARK is a good position to check for intermittent open circuits (with scan tool monitoring TRD). ^ TR4, TR3A, TR2 and TR1 are all open in OVERDRIVE, so OVERDRIVE is a good position to check for shorts to ground. To determine the shorted components while observing TRD, unplug the TR and determine if the short goes away. If the short is still present unplug the transmission harness and determine if the short goes away. If the short is still present, then the short is in the PCM or vehicle harness. Remove the suspect circuit(s) wire terminal from the PCM connector. If the short is still present, then the PCM has an internal failure, otherwise the failure is in the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Starter Relay Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Starter Relay > Page 6308 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Run/Start Relay Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Run/Start Relay > Page 6311 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair Battery Cable: Service and Repair BATTERY CABLES Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Page 6316 Part 2 Removal and Installation 1. Disconnect the battery. 2. With the vehicle in NEUTRAL, position it on a hoist. 3. Remove the starter solenoid terminals protective cap. 4. Remove the starter solenoid wire cable terminal nut. - To install, tighten to 6 Nm (53 lb-in). 5. Remove the starter solenoid positive cable terminal nut. - To install, tighten to 9 Nm (80 lb-in). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Page 6317 6. Disconnect the starter solenoid wire cable terminal. 7. Disconnect the starter solenoid positive cable terminal. 8. Remove the nut and disconnect the starter motor ground cable terminal. - To install, tighten to 20 Nm (15 lb-ft). 9. Disconnect the power steering pressure switch electrical connector. 10. Disconnect the A/C compressor electrical connector. 11. Disconnect the oil pressure sending unit electrical connector. 12. Remove the nut and position the battery cable engine front cover bracket aside. - To install, tighten to 20 Nm (15 lb-ft). 13. Remove the nut and position the battery cable frame bracket aside. - To install, tighten to 9 Nm (80 lb-in). 14. Release the battery cable harness locators from the front of the engine. 15. Disconnect the 2 generator electrical connectors. 16. Position the protective cover aside, remove the nut and position the generator B+ terminal aside. - To install, tighten to 9 Nm (80 lb-in). 17. Release the battery cable harness locator from the generator harness guide. 18. Open the BJB cover and remove the 2 BJB nuts. - To install, tighten to 9 Nm (80 lb-in). 19. Disconnect the BJB terminal. 20. Remove the nut and position the battery cable body ground terminal aside. - To install, tighten to 9 Nm (80 lb-in). 21. Remove the 2 battery cable harness locators from the battery tray. 22. Disconnect the battery cable harness electrical connector. 23. Remove the battery cables. 24. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications Alternator: Electrical Specifications Item....................................................................................................................................................... ..............................................................Specification Generator Voltage................................................................................................................................................. ........................................................................12 volts Generator amps.............................................................................70/121 amps (max) @ 1,800-6,000 generator rpm, approximately 500-2,000 engine rpm Load at 2,000 rpm................................................................................................................................ ........................................................................70 amps No Load at 2,000 rpm.................................... ...............................................................................................................................between 13.2 and 15.5 volts Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications > Page 6323 Torque Specifications Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions Alternator: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6326 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6327 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6328 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6329 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6330 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6331 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6332 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6333 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6334 Alternator: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6335 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6336 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6337 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6338 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6339 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6340 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6341 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6342 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6343 Alternator: Connector Views C102A C102B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6344 C102C C1104A Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 6345 C1104B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 6346 Alternator: Application and ID Item....................................................................................................................................................... ..............................................................Specification Generator Rating........................................................................................................70/121 amp (max) @ 1,800-6,000 generator rpm, approx. 500-2,000 engine rpm Generator pulley ratio............................. .............................................................................................................................................................. ..........2.59:1 Voltage regulator type..................................................................................................... .....................................................Electronic internal with generator Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 6347 Alternator: Description and Operation GENERATOR The generator is belt-driven by the engine accessory drive system. The generator has an internal voltage regulator that is not replaced Separately. The generator and voltage regulator are repaired as an assembly. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 6348 Alternator: Service and Repair GENERATOR Removal and Installation 1. Disconnect the battery. 2. Rotate the front end accessory drive belt tensioner counterclockwise and position the front end accessory drive belt aside. 3. Position the protective cover aside and remove and discard the generator B+ terminal nut. - To install, tighten to 8 Nm (71 lb-in). 4. Disconnect the generator B+ terminal and the 2 electrical connectors. 5. Remove the 3 bolts and the generator. - To install, tighten to 47 Nm (35 lb-ft). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 6349 6. If necessary, remove the nut and the generator pulley. - To install, tighten to 109 Nm (80 lb-ft). 7. If necessary, remove the cap and nut and position the radial adapter aside. - To install, tighten to 11 Nm (8 lb-ft). 8. To install, reverse the removal procedure. - Install a new generator B+ terminal nut. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Service and Repair Voltage Regulator: Service and Repair VOLTAGE REGULATOR Removal and Installation 1. Remove the generator. 2. Remove the 4 screws and the generator voltage regulator (includes the generator brush and terminal holder). - To install, tighten to 3 Nm (27 lb-in). 3. NOTE: When installing the voltage regulator (including the generator brush and terminal holder) assembly, it is necessary to insert a wire (preferably plastic) into the generator brush holding wire insertion hole in order to hold the generator brushes while the voltage regulator assembly (including the generator brush and terminal holder) is being assembled to the generator. Make certain to remove the wire before the vehicle is started or the generator will not operate. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair Ignition Lock: Service and Repair IGNITION LOCK CYLINDER Removal and Installation NOTE: - When any new lock cylinder is installed, the driver door and ignition lock cylinders should be installed as a set. This eliminates carrying an extra key which fits only 1 lock. If a new key is used, 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. With the ignition switch in the ON position, press the locking pin with a suitable tool and remove the ignition lock cylinder. 2. To install, reverse the removal procedure. - Lubricate the ignition lock cylinder during installation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER Removal and Installation NOTE: - When any new lock cylinder is installed, the driver door and ignition lock cylinders should be installed as a set. This eliminates carrying an extra key which fits only 1 lock. If a new key is used, 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. With the ignition switch in the ON position, press the locking pin with a suitable tool and remove the ignition lock cylinder. 2. To install, reverse the removal procedure. - Lubricate the ignition lock cylinder during installation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement Technical Service Bulletin # 09B11 Date: 100115 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on January 15, 2010. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 6369 FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website on January 15, 2010. Owner names and addresses will be available on January 31, 2010. 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 program 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 field service action. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected customers whose vehicles are not on your VIN list 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 service action. 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 service action 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 ^ Ford Motor Company will only refund owner-paid repairs covered by this program if the repair was performed before the date of the Owner Notification Letter. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ If a "stuck in park" event occurs, customers can override the brake shift interlock with information located in the Owner Guide. The 09B11 Owner Letter provides directions to locate the override information and includes a representative brake shift interlock owner guide attachment. There should be no emergency repair refunds after the customer mailings are complete. ^ Refunds will only be provided for the cost associated with the diagnosis and replacement of the transmission gearshift lever due to a "stuck in park" concern. ^ 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. ^ The refund period for repairs performed prior to the date of the Owner Notification Letter will expire on July 31, 2010. ^ Refund Claiming Information (submit on separate repair line). - Program Code: 09B11 - 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 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 6370 ^ 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 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. ^ Refer to ACESII manual for claims preparation and submission information. ^ PROGRAM TERMS: This program will be in effect until January 31, 2011 regardless of mileage. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this recall is 50415. DEALER PRICE For latest prices, 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 In some of the affected vehicles, the transmission gearshift lever may not move out of the park position even when the brake pedal is depressed. This "stuck in park" condition can develop due to silicon dioxide contamination building up on the contacts of the park detect switch located on the transmission gearshift lever. SERVICE PROCEDURE 1. Remove the front floor console. Refer to the appropriate WSM Section 501-12 Console - Front. 2. NOTICE: Electronic modules are sensitive to static electrical charges If the new circuit board is exposed to these charges, damage may result The circuit board should be handled by the plastic connector(s) and avoid touching any of the metal surfaces. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 6371 Disconnect the three electrical connectors from the white circuit board that is located on the lower RH section of the transmission gearshift lever See Figure 1. 3. Remove the circuit board case from the RH side of the transmission gearshift lever by releasing the two retainer clips See Figure 2. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 6372 4. Replace the circuit board See Figure 3. ^ Separate the upper circuit board case cover from the lower case containing the circuit board. ^ Remove and discard the circuit board Install the new circuit board. Snap the upper circuit board case cover and the lower case back together. 5. To reinstall the circuit board case, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 6373 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 6374 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 6375 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign A/T Shift Lever Circuit Board Replacement Technical Service Bulletin # 09B11 Date: 100115 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on January 15, 2010. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign A/T Shift Lever Circuit Board Replacement > Page 6381 FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website on January 15, 2010. Owner names and addresses will be available on January 31, 2010. 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 program 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 field service action. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected customers whose vehicles are not on your VIN list 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 service action. 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 service action 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 ^ Ford Motor Company will only refund owner-paid repairs covered by this program if the repair was performed before the date of the Owner Notification Letter. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ If a "stuck in park" event occurs, customers can override the brake shift interlock with information located in the Owner Guide. The 09B11 Owner Letter provides directions to locate the override information and includes a representative brake shift interlock owner guide attachment. There should be no emergency repair refunds after the customer mailings are complete. ^ Refunds will only be provided for the cost associated with the diagnosis and replacement of the transmission gearshift lever due to a "stuck in park" concern. ^ 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. ^ The refund period for repairs performed prior to the date of the Owner Notification Letter will expire on July 31, 2010. ^ Refund Claiming Information (submit on separate repair line). - Program Code: 09B11 - 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 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign A/T Shift Lever Circuit Board Replacement > Page 6382 ^ 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 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. ^ Refer to ACESII manual for claims preparation and submission information. ^ PROGRAM TERMS: This program will be in effect until January 31, 2011 regardless of mileage. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this recall is 50415. DEALER PRICE For latest prices, 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 In some of the affected vehicles, the transmission gearshift lever may not move out of the park position even when the brake pedal is depressed. This "stuck in park" condition can develop due to silicon dioxide contamination building up on the contacts of the park detect switch located on the transmission gearshift lever. SERVICE PROCEDURE 1. Remove the front floor console. Refer to the appropriate WSM Section 501-12 Console - Front. 2. NOTICE: Electronic modules are sensitive to static electrical charges If the new circuit board is exposed to these charges, damage may result The circuit board should be handled by the plastic connector(s) and avoid touching any of the metal surfaces. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign A/T Shift Lever Circuit Board Replacement > Page 6383 Disconnect the three electrical connectors from the white circuit board that is located on the lower RH section of the transmission gearshift lever See Figure 1. 3. Remove the circuit board case from the RH side of the transmission gearshift lever by releasing the two retainer clips See Figure 2. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign A/T Shift Lever Circuit Board Replacement > Page 6384 4. Replace the circuit board See Figure 3. ^ Separate the upper circuit board case cover from the lower case containing the circuit board. ^ Remove and discard the circuit board Install the new circuit board. Snap the upper circuit board case cover and the lower case back together. 5. To reinstall the circuit board case, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign A/T Shift Lever Circuit Board Replacement > Page 6385 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign A/T Shift Lever Circuit Board Replacement > Page 6386 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign A/T Shift Lever Circuit Board Replacement > Page 6387 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Technical Service Bulletins > Page 6388 View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Technical Service Bulletins > Page 6389 C167 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Technical Service Bulletins > Page 6390 Neutral Safety Switch: Testing and Inspection Digital Transmission Range (TR) Sensor Diagnosis Chart Digital Transmission Range (TR) Sensor Diagnosis Chart Wiggle Test Information for Open/Shorts ^ TR4, TR3A, TR2 and TR1 are all closed in PARK. PARK is a good position to check for intermittent open circuits (with scan tool monitoring TRD). ^ TR4, TR3A, TR2 and TR1 are all open in OVERDRIVE, so OVERDRIVE is a good position to check for shorts to ground. To determine the shorted components while observing TRD, unplug the TR and determine if the short goes away. If the short is still present unplug the transmission harness and determine if the short goes away. If the short is still present, then the short is in the PCM or vehicle harness. Remove the suspect circuit(s) wire terminal from the PCM connector. If the short is still present, then the PCM has an internal failure, otherwise the failure is in the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > Customer Interest for Starter Cable: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition Starter Cable: Customer Interest Starting System- No Crank Condition TSB 06-19-14 10/02/06 NO CRANK / STARTER TERMINAL FATIGUE FORD: 1997-2007 Crown Victoria 1997-2004 F-150 Heritage 1997-2006 Expedition 1998-2006 E-Series 1999-2006 F-Super Duty 2002-2007 Explorer 2004-2006 F-150 2007 Explorer Sport Trac LINCOLN: 1998-2006 Navigator 2003-2005 Aviator MERCURY: 1997-2007 Grand Marquis 2002-2007 Mountaineer ISSUE Some vehicles may exhibit a no crank condition due to an open circuit in the starter relay to starter motor circuit at the starter motor connection. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE A new starter terminal wiring pigtail kit is released eliminating the need to replace the entire harness for the terminal connection. NOTE TERMINAL KIT ONLY SERVICES THE STARTER RELAY TO STARTER MOTOR CIRCUIT. THE KIT DOES NOT SERVICE STARTER MOTOR BATTERY POWER CIRCUIT. Refer to instruction sheet contained in Wiring Pigtail Kit for wiring harness service procedure. NOTE REFERENCE THE APPROPRIATE WORKSHOP MANUAL SERVICE SECTION 303-06 FOR REMOVAL AND INSTALLATION OF THE STARTER MOTOR WIRING TERMINAL CONNECTION PROCEDURES. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061914A Install Wiring Pigtail kit (Do 0.4 Hr. Not Use With 14200A) MT061914 Claim Additional Labor Actual Required As Actual Time Time Or Use SLTS Operation If Available DEALER CODING Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > Customer Interest for Starter Cable: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition > Page 6399 CONDITION BASIC PART NO. CODE 14A280 01 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Starter Cable: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition Starter Cable: All Technical Service Bulletins Starting System- No Crank Condition TSB 06-19-14 10/02/06 NO CRANK / STARTER TERMINAL FATIGUE FORD: 1997-2007 Crown Victoria 1997-2004 F-150 Heritage 1997-2006 Expedition 1998-2006 E-Series 1999-2006 F-Super Duty 2002-2007 Explorer 2004-2006 F-150 2007 Explorer Sport Trac LINCOLN: 1998-2006 Navigator 2003-2005 Aviator MERCURY: 1997-2007 Grand Marquis 2002-2007 Mountaineer ISSUE Some vehicles may exhibit a no crank condition due to an open circuit in the starter relay to starter motor circuit at the starter motor connection. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE A new starter terminal wiring pigtail kit is released eliminating the need to replace the entire harness for the terminal connection. NOTE TERMINAL KIT ONLY SERVICES THE STARTER RELAY TO STARTER MOTOR CIRCUIT. THE KIT DOES NOT SERVICE STARTER MOTOR BATTERY POWER CIRCUIT. Refer to instruction sheet contained in Wiring Pigtail Kit for wiring harness service procedure. NOTE REFERENCE THE APPROPRIATE WORKSHOP MANUAL SERVICE SECTION 303-06 FOR REMOVAL AND INSTALLATION OF THE STARTER MOTOR WIRING TERMINAL CONNECTION PROCEDURES. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061914A Install Wiring Pigtail kit (Do 0.4 Hr. Not Use With 14200A) MT061914 Claim Additional Labor Actual Required As Actual Time Time Or Use SLTS Operation If Available DEALER CODING Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Starter Cable: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition > Page 6405 CONDITION BASIC PART NO. CODE 14A280 01 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > Customer Interest: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition Starter Motor: Customer Interest Starting System- No Crank Condition TSB 06-19-14 10/02/06 NO CRANK / STARTER TERMINAL FATIGUE FORD: 1997-2007 Crown Victoria 1997-2004 F-150 Heritage 1997-2006 Expedition 1998-2006 E-Series 1999-2006 F-Super Duty 2002-2007 Explorer 2004-2006 F-150 2007 Explorer Sport Trac LINCOLN: 1998-2006 Navigator 2003-2005 Aviator MERCURY: 1997-2007 Grand Marquis 2002-2007 Mountaineer ISSUE Some vehicles may exhibit a no crank condition due to an open circuit in the starter relay to starter motor circuit at the starter motor connection. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE A new starter terminal wiring pigtail kit is released eliminating the need to replace the entire harness for the terminal connection. NOTE TERMINAL KIT ONLY SERVICES THE STARTER RELAY TO STARTER MOTOR CIRCUIT. THE KIT DOES NOT SERVICE STARTER MOTOR BATTERY POWER CIRCUIT. Refer to instruction sheet contained in Wiring Pigtail Kit for wiring harness service procedure. NOTE REFERENCE THE APPROPRIATE WORKSHOP MANUAL SERVICE SECTION 303-06 FOR REMOVAL AND INSTALLATION OF THE STARTER MOTOR WIRING TERMINAL CONNECTION PROCEDURES. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061914A Install Wiring Pigtail kit (Do 0.4 Hr. Not Use With 14200A) MT061914 Claim Additional Labor Actual Required As Actual Time Time Or Use SLTS Operation If Available DEALER CODING Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > Customer Interest: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition > Page 6414 CONDITION BASIC PART NO. CODE 14A280 01 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition Starter Motor: All Technical Service Bulletins Starting System- No Crank Condition TSB 06-19-14 10/02/06 NO CRANK / STARTER TERMINAL FATIGUE FORD: 1997-2007 Crown Victoria 1997-2004 F-150 Heritage 1997-2006 Expedition 1998-2006 E-Series 1999-2006 F-Super Duty 2002-2007 Explorer 2004-2006 F-150 2007 Explorer Sport Trac LINCOLN: 1998-2006 Navigator 2003-2005 Aviator MERCURY: 1997-2007 Grand Marquis 2002-2007 Mountaineer ISSUE Some vehicles may exhibit a no crank condition due to an open circuit in the starter relay to starter motor circuit at the starter motor connection. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE A new starter terminal wiring pigtail kit is released eliminating the need to replace the entire harness for the terminal connection. NOTE TERMINAL KIT ONLY SERVICES THE STARTER RELAY TO STARTER MOTOR CIRCUIT. THE KIT DOES NOT SERVICE STARTER MOTOR BATTERY POWER CIRCUIT. Refer to instruction sheet contained in Wiring Pigtail Kit for wiring harness service procedure. NOTE REFERENCE THE APPROPRIATE WORKSHOP MANUAL SERVICE SECTION 303-06 FOR REMOVAL AND INSTALLATION OF THE STARTER MOTOR WIRING TERMINAL CONNECTION PROCEDURES. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061914A Install Wiring Pigtail kit (Do 0.4 Hr. Not Use With 14200A) MT061914 Claim Additional Labor Actual Required As Actual Time Time Or Use SLTS Operation If Available DEALER CODING Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition > Page 6420 CONDITION BASIC PART NO. CODE 14A280 01 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Starter Motor: > 07-20-6 > Oct > 07 > Body - Water Leak In The Headliner/Dome Lamp Area Sunroof / Moonroof Drain: All Technical Service Bulletins Body - Water Leak In The Headliner/Dome Lamp Area TSB 07-20-6 10/15/07 WATER LEAK IN HEADLINER/DOME LAMP AREA - VEHICLES EQUIPPED WITH ROOF OPENING PANEL AND SAFETY CANOPY AIR BAG SYSTEMS - BUILT BEFORE 3/27/2007 FORD: 2006-2007 Explorer MERCURY: 2006-2007 Mountaineer This article supersedes TSB 06-21-17 to update the Part List and Service Procedure. ISSUE Some 2006-2007 Explorer and Mountaineer vehicles built prior to 3/27/2007 and equipped with factory installed roof opening panel and safety canopy air bag system may have water leaking in the headliner dome lamp area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE The procedure will reroute roof opening panel drain hoses to provide downward slope for improved drainage. 1. Remove headliner following Workshop Manual (WSM), Section 501-05. 2. Remove rear portion of drain hose from clip and remove retaining clip. NOTE IF A HOLE HAS BEEN DRILLED IN THE LOWER REAR CORNER OF THE RECTANGLE BRACKET (FIGURE 1) GO TO STEP 5. IF THE VEHICLE WAS BUILD AFTER 8/14/2006 DRILLING A 1/4" HOLE IS NOT REQUIRED. 3. Drill a 1/4" (6.7 mm) hole, 3/4" (20 mm) rearward from the lower rear corner of the rectangle. (Figure 1) CAUTION TO PREVENT DAMAGE TO OUTER SKIN SHEET METAL USE A DRILL STOP AND DO NOT ALLOW THE DRILL BIT TO STRIKE OUTER PANEL AS IT PASSES THROUGH THE INNER PANEL. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Starter Motor: > 07-20-6 > Oct > 07 > Body - Water Leak In The Headliner/Dome Lamp Area > Page 6426 4. Remove the rear drain tube. Attach hose clip to existing hole for vehicle built after 8/14/2006. For all other vehicles attach the hose clip in the new hole. (Figure 2) 5. Install the updated drain tube. 6. Attach the hose clip to the coat hook support bracket. (Figure 3) NOTE Make sure the drain hose is placed under the coat hook bracket. (Figure 3) 7. Make sure there is no slack left in the hose as it leads up to the roof opening panel module. (Figure 3) 8. Repeat procedure on opposite side. 9. Install headliner following WSM, Section 501-05. Parts Block 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 072006A 2006-2007 Built Before 1.9 Hrs. 3/27/2007 With Roof Opening Panel And Safety Canopy: Install The Updated Drain Tubes Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Starter Motor: > 07-20-6 > Oct > 07 > Body - Water Leak In The Headliner/Dome Lamp Area > Page 6427 Following Service Procedure, Includes Time To Remove And Install Headliner And DVD Player If Equipped (Do Not Use With 51916A, 51916B, 51916AZV, 51916BZV) DEALER CODING CONDITION BASIC PART NO. CODE 78502C53 12 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Starter Motor: > 07-20-6 > Oct > 07 > Body - Water Leak In The Headliner/Dome Lamp Area > Page 6433 4. Remove the rear drain tube. Attach hose clip to existing hole for vehicle built after 8/14/2006. For all other vehicles attach the hose clip in the new hole. (Figure 2) 5. Install the updated drain tube. 6. Attach the hose clip to the coat hook support bracket. (Figure 3) NOTE Make sure the drain hose is placed under the coat hook bracket. (Figure 3) 7. Make sure there is no slack left in the hose as it leads up to the roof opening panel module. (Figure 3) 8. Repeat procedure on opposite side. 9. Install headliner following WSM, Section 501-05. Parts Block 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 072006A 2006-2007 Built Before 1.9 Hrs. 3/27/2007 With Roof Opening Panel And Safety Canopy: Install The Updated Drain Tubes Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Starter Motor: > 07-20-6 > Oct > 07 > Body - Water Leak In The Headliner/Dome Lamp Area > Page 6434 Following Service Procedure, Includes Time To Remove And Install Headliner And DVD Player If Equipped (Do Not Use With 51916A, 51916B, 51916AZV, 51916BZV) DEALER CODING CONDITION BASIC PART NO. CODE 78502C53 12 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Electrical Specifications Starter Motor: Electrical Specifications Item....................................................................................................................................................... ..............................................................Specification Normal engine cranking speed............................................................................................................. ................................................................140-220 rpm Starter motor no load current draw................. ........................................................................................................................................................6080 amps Starter motor normal load current draw................................................................................. .............................................................................130-220 amps Starter motor maximum load current draw.......................................................................................................................................... ......................800 amps Starter motor minimum stall torque (at 5 volts)........................................................................................................................................14.7 Nm (10.8 lb-ft) Starter circuit maximum voltage drop (engine at normal operating temperature).........................................................................................................0.5 volt Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Electrical Specifications > Page 6437 Torque Specifications Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 6438 View 151-2 (Engine Compartment - 4.0L, (2 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 6439 Starter Motor: Diagrams C197A C197B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 6440 Starter Motor: Service and Repair STARTER MOTOR Removal and Installation WARNING: When carrying out maintenance on the starting system, be aware that heavy gauge leads are connected directly to the battery. Make sure protective caps are in place when maintenance is completed. Failure to follow these instructions may result in personal injury. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the starter motor solenoid terminal cover. 4. Remove the B-terminal nut and disconnect the cable. - To install, tighten to 12 Nm (9 lb-ft). 5. Remove the S-terminal nut and disconnect the cable. - To install, tighten to 6 Nm (53 lb-in). 6. Remove the nut and position the ground cable aside. 7. Remove the bolt, the stud bolt and the starter. - To install, tighten to 25 Nm (18 lb-ft). 8. To install, reverse the removal procedure. - Tighten the upper bolt before tightening the lower fastener. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Starter Relay Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Starter Relay > Page 6445 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and Inspection > Run/Start Relay Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and Inspection > Run/Start Relay > Page 6448 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Console 1 C3063 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Console 1 > Page 6454 C3064 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 6455 Auxiliary Power Outlet: Service and Repair PICKUP BED POWER POINT Removal and Installation 1. Remove the 4 screws and the power point receptacle from the pickup bed side. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 6456 2. Disconnect the power point receptacle electrical connector and remove the power point receptacle. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor #1 C174 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor #1 > Page 6461 C194 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Fuse: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6466 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6467 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6468 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6469 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6470 Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6471 Battery Junction Box (BJB) / Power Distribution Box - Early Production Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6472 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6473 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6474 Battery Junction Box (BJB) / Power Distribution Box - Late Production Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6475 Fuse: Locations Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6478 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6479 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6480 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6481 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6482 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6483 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6484 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6485 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6486 Fuse: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6487 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6488 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6489 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6490 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6491 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6492 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6493 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6494 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Fuse: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6497 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6498 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6499 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6500 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6501 Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6502 Battery Junction Box (BJB) / Power Distribution Box - Early Production Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6503 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6504 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6505 Battery Junction Box (BJB) / Power Distribution Box - Late Production Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6506 Fuse: Application and ID Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Fuse Block: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6511 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6512 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6513 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6514 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6515 Fuse Block: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6516 Battery Junction Box (BJB) / Power Distribution Box - Early Production Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6517 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6518 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6519 Battery Junction Box (BJB) / Power Distribution Box - Late Production Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6520 Fuse Block: Locations Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6523 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6524 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6525 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6526 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6527 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6528 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6529 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6530 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6531 Fuse Block: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6532 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6533 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6534 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6535 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6536 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6537 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6538 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6539 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6540 Fuse Block: Connector Views C1035A C1035B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6541 C2280A Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6542 C2280B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6543 C2280C Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6544 C2280D Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6545 C2280E Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Fuse Block: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6548 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6549 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6550 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6551 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6552 Fuse Block: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6553 Battery Junction Box (BJB) / Power Distribution Box - Early Production Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6554 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6555 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6556 Battery Junction Box (BJB) / Power Distribution Box - Late Production Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6557 Fuse Block: Application and ID Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 Multiple Junction Connector: Diagrams C110-C339 C110 C126 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6568 C133 C134 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6569 C139 C140 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6570 C144 C145 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6571 C146 C192 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6572 C210 (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6573 C210 (Part 2) C211 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6574 C212 C213 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6575 C214 (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6576 C214 (Part 2) C215 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6577 C219 C237 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6578 C238 C248 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6579 C311 (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6580 C311 (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6581 C312 (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6582 C312 (Part 2) C313 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6583 C314 C315 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6584 C327 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6585 C328 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6586 C339 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6587 Multiple Junction Connector: Diagrams C340-C4000 C340 C405 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6588 C406 C408 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6589 C410 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6590 C411 C421 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6591 C422 C423 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6592 C431 C432 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6593 C438 C465 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6594 C494 C495 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6595 C510 C511 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6596 C610 C700 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6597 C800 C913 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6598 C925 C3007 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6599 C3047 C3049 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6600 C3050 C4000 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 6604 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 6615 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 / Smart Junction Box (SJB) Relay Box: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 / Smart Junction Box (SJB) > Page 6620 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 / Smart Junction Box (SJB) > Page 6621 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 / Smart Junction Box (SJB) > Page 6622 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 / Smart Junction Box (SJB) > Page 6623 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 / Smart Junction Box (SJB) > Page 6624 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 / Smart Junction Box (SJB) > Page 6625 Battery Junction Box (BJB) / Power Distribution Box - Early Production Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 / Smart Junction Box (SJB) > Page 6626 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 / Smart Junction Box (SJB) > Page 6627 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 / Smart Junction Box (SJB) > Page 6628 Battery Junction Box (BJB) / Power Distribution Box - Late Production Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 / Smart Junction Box (SJB) > Page 6629 Relay Box: Locations Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) Relay Box: Diagrams Battery Junction Box (BJB) C1035A C1035B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6632 Relay Box: Diagrams Smart Junction Box (SJB) C2280A Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6633 C2280B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6634 C2280C Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6635 C2280D Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6636 C2280E Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 / Smart Junction Box (SJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 / Smart Junction Box (SJB) > Page 6639 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 / Smart Junction Box (SJB) > Page 6640 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 / Smart Junction Box (SJB) > Page 6641 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 / Smart Junction Box (SJB) > Page 6642 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 / Smart Junction Box (SJB) > Page 6643 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 / Smart Junction Box (SJB) > Page 6644 Battery Junction Box (BJB) / Power Distribution Box - Early Production Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 / Smart Junction Box (SJB) > Page 6645 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 / Smart Junction Box (SJB) > Page 6646 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 / Smart Junction Box (SJB) > Page 6647 Battery Junction Box (BJB) / Power Distribution Box - Late Production Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 / Smart Junction Box (SJB) > Page 6648 Relay Box: Application and ID Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Relay Box: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6653 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6654 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6655 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6656 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6657 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6658 Battery Junction Box (BJB) / Power Distribution Box - Early Production Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6659 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6660 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6661 Battery Junction Box (BJB) / Power Distribution Box - Late Production Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6662 Relay Box: Locations Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) Relay Box: Diagrams Battery Junction Box (BJB) C1035A C1035B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6665 Relay Box: Diagrams Smart Junction Box (SJB) C2280A Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6666 C2280B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6667 C2280C Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6668 C2280D Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6669 C2280E Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6672 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6673 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6674 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6675 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6676 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6677 Battery Junction Box (BJB) / Power Distribution Box - Early Production Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6678 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6679 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6680 Battery Junction Box (BJB) / Power Distribution Box - Late Production Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6681 Relay Box: Application and ID Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Console 1 C3063 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Console 1 > Page 6687 C3064 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 6688 Auxiliary Power Outlet: Service and Repair PICKUP BED POWER POINT Removal and Installation 1. Remove the 4 screws and the power point receptacle from the pickup bed side. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 6689 2. Disconnect the power point receptacle electrical connector and remove the power point receptacle. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor #1 C174 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor #1 > Page 6694 C194 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Fuse: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6699 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6700 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6701 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6702 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6703 Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6704 Battery Junction Box (BJB) / Power Distribution Box - Early Production Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6705 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6706 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6707 Battery Junction Box (BJB) / Power Distribution Box - Late Production Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6708 Fuse: Locations Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6711 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6712 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6713 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6714 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6715 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6716 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6717 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6718 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6719 Fuse: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6720 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6721 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6722 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6723 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6724 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6725 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6726 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6727 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Fuse: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6730 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6731 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6732 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6733 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6734 Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6735 Battery Junction Box (BJB) / Power Distribution Box - Early Production Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6736 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6737 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6738 Battery Junction Box (BJB) / Power Distribution Box - Late Production Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6739 Fuse: Application and ID Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Fuse Block: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6744 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6745 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6746 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6747 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6748 Fuse Block: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6749 Battery Junction Box (BJB) / Power Distribution Box - Early Production Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6750 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6751 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6752 Battery Junction Box (BJB) / Power Distribution Box - Late Production Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6753 Fuse Block: Locations Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6756 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6757 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6758 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6759 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6760 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6761 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6762 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6763 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6764 Fuse Block: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6765 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6766 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6767 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6768 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6769 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6770 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6771 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6772 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6773 Fuse Block: Connector Views C1035A C1035B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6774 C2280A Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6775 C2280B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6776 C2280C Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6777 C2280D Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6778 C2280E Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Fuse Block: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6781 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6782 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6783 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6784 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6785 Fuse Block: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6786 Battery Junction Box (BJB) / Power Distribution Box - Early Production Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6787 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6788 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6789 Battery Junction Box (BJB) / Power Distribution Box - Late Production Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6790 Fuse Block: Application and ID Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 Multiple Junction Connector: Diagrams C110-C339 C110 C126 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6801 C133 C134 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6802 C139 C140 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6803 C144 C145 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6804 C146 C192 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6805 C210 (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6806 C210 (Part 2) C211 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6807 C212 C213 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6808 C214 (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6809 C214 (Part 2) C215 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6810 C219 C237 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6811 C238 C248 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6812 C311 (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6813 C311 (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6814 C312 (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6815 C312 (Part 2) C313 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6816 C314 C315 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6817 C327 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6818 C328 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6819 C339 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6820 Multiple Junction Connector: Diagrams C340-C4000 C340 C405 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6821 C406 C408 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6822 C410 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6823 C411 C421 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6824 C422 C423 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6825 C431 C432 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6826 C438 C465 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6827 C494 C495 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6828 C510 C511 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6829 C610 C700 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6830 C800 C913 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6831 C925 C3007 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6832 C3047 C3049 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C339 > Page 6833 C3050 C4000 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 6837 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 6848 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Relay Box: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6853 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6854 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6855 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6856 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6857 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6858 Battery Junction Box (BJB) / Power Distribution Box - Early Production Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6859 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6860 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6861 Battery Junction Box (BJB) / Power Distribution Box - Late Production Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6862 Relay Box: Locations Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) Relay Box: Diagrams Battery Junction Box (BJB) C1035A C1035B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6865 Relay Box: Diagrams Smart Junction Box (SJB) C2280A Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6866 C2280B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6867 C2280C Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6868 C2280D Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6869 C2280E Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 / Smart Junction Box (SJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 / Smart Junction Box (SJB) > Page 6872 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 / Smart Junction Box (SJB) > Page 6873 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 / Smart Junction Box (SJB) > Page 6874 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 / Smart Junction Box (SJB) > Page 6875 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 / Smart Junction Box (SJB) > Page 6876 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 / Smart Junction Box (SJB) > Page 6877 Battery Junction Box (BJB) / Power Distribution Box - Early Production Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 / Smart Junction Box (SJB) > Page 6878 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 / Smart Junction Box (SJB) > Page 6879 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 / Smart Junction Box (SJB) > Page 6880 Battery Junction Box (BJB) / Power Distribution Box - Late Production Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 / Smart Junction Box (SJB) > Page 6881 Relay Box: Application and ID Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Relay Box: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6886 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6887 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6888 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6889 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6890 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6891 Battery Junction Box (BJB) / Power Distribution Box - Early Production Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6892 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6893 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6894 Battery Junction Box (BJB) / Power Distribution Box - Late Production Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6895 Relay Box: Locations Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) Relay Box: Diagrams Battery Junction Box (BJB) C1035A C1035B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6898 Relay Box: Diagrams Smart Junction Box (SJB) C2280A Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6899 C2280B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6900 C2280C Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6901 C2280D Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6902 C2280E Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Location Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6905 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6906 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6907 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6908 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6909 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6910 Battery Junction Box (BJB) / Power Distribution Box - Early Production Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6911 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6912 Fuse Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6913 Battery Junction Box (BJB) / Power Distribution Box - Late Production Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6914 Relay Box: Application and ID Auxiliary Relay Box 1 Auxiliary Relay Box 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 6920 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 6921 Alignment: Specifications General Specifications General Specifications General Specifications (Part 1) General Specifications (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 6922 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 6923 Alignment: Specifications General Specifications General Specifications General Specifications (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 6924 General Specifications (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6925 Alignment: Description and Operation Suspension System The front camber and caster are adjusted by loosening the upper control arm bolts which will allow the upper arm to be moved in the slotted frame holes. The LF caster can be adjusted by loosening the lower control arm rearward nut to allow the lower arm to be moved in the slotted frame hole. Front toe is adjusted by the use of the front wheel spindle tie rods. The rear camber is adjusted by replacing the upper arm inboard flag nut with a non-flag nut to allow the arm to be adjusted in the slotted frame holes. The rear toe is adjusted through the use of the rear toe link cam bolt. 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 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. Toe Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6926 Positive Toe (Toe In) 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. Ride Height Front Ride Height Measurement Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6927 Rear Ride Height Measurement Thrust Angle (Dogtracking) Thrust Angle (Dogtracking) Thrust angle (also known as dogtracking) is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can give the illusion of incorrect thrust angle. 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. 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. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6928 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 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. 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, such as wind or road camber. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front Alignment: Service and Repair Camber and Caster Adjustment - Front Camber and Caster Adjustment - Front 1. Using alignment equipment and the manufacturer's instructions, measure the front caster and camber. 2. Loosen the upper arm bolt(s) and adjust the caster and camber settings. Refer to the chart. ^ When making adjustments that require moving both the front and the rear of the upper arm, move both ends of the arm equally. 3. NOTE: Make sure that the weight of the vehicle is on the wheels and that the caster and camber settings are not disturbed while tightening the bolt(s). Tighten the upper arm bolt(s) to 150 Nm (111 ft. lbs.) 4. NOTE: A caster split adjustment can be made by loosening the LF lower arm rearward nut and adjusting the rear of the LF lower arm. Remove and discard the LF lower control arm rearward nut. 5. NOTE: Do not fully tighten the nut and bolt at this time. Install a new LF lower control arm rearward nut. 6. Position the LF lower control arm until the caster split is within specification. 7. NOTE: Make sure that the weight of the vehicle is on the wheels and that the caster settings are not disturbed while tightening the nut. Tighten the LF lower control arm rearward nut to 200 Nm (148 ft. lbs.) 8. Recheck the camber and caster, adjust as necessary. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front > Page 6931 9. Check and, if necessary, adjust the front toe. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front > Page 6932 Alignment: Service and Repair Toe Adjustment - Front Toe Adjustment - Front 1. Using alignment equipment and the manufacturer's instructions, measure the front toe. 2. Start the engine and center the steering wheel. 3. Turn the engine OFF and, using a suitable holding device, lock the steering wheel in the straight ahead position. 4. NOTE: Do not allow the steering gear bellows to twist when the front wheel inner tie rod is rotated. Remove the clamps. 5. Loosen the tie-rod jam nuts.Rotate the front wheel inner tie rods until the toe setting is within specification. 6. CAUTION: Make sure to hold the tie-rod end stationary while tightening the nut or damage to the steering gear bellows can occur. NOTE: Make sure that the toe settings are not disturbed while tightening the nuts. Tighten the tie-rod jam nuts to 70 Nm (52 ft. lbs.) 7. Install the clamps. 8. Recheck the toe settings and adjust if necessary. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front > Page 6933 Alignment: Service and Repair Toe Adjustment - Rear Toe Adjustment - Rear 1. Using alignment equipment and the manufacturer's instructions, measure the rear toe. 2. Start the engine and center the steering wheel. 3. Turn the engine OFF and, using a suitable holding device, lock the steering wheel in the straight ahead position. 4. Loosen the rear toe link inboard nut. 5. Rotate the rear toe link cam bolt until the toe setting is within specification. 6. NOTE: Make sure the toe settings are not disturbed while tightening the nut. While holding the adjustment cam bolt, tighten the toe link inboard nut. ^ Tighten to 275 Nm (202 ft. lbs.) 7. Recheck the toe settings and adjust if necessary. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front > Page 6934 Alignment: Service and Repair Camber Adjustment - Rear Camber Adjustment - Rear 1. Index-mark the upper arm inboard bolt to the frame. 2. NOTE: The upper arm inboard flag nut must be removed and replaced with a non-flag nut to allow for the adjustment of the arm in the frame slot. Remove and discard the upper arm inboard bolt and flagnut. ^ Install a new non-flagnut.Using alignment equipment and the manufacturer's instructions, measure the rear camber. 3. NOTE: The weight of the vehicle must be off of the wheels in order to adjust the rear camber. NOTE: For camber adjustment, 1 mm (0.03 inch) of movement equals 0.24 degrees of camber. NOTE: To decrease the camber, move the upper arm inward. To increase the camber, move the upper arm outward. Position the upper arm until the camber setting is within specification. 4. NOTE: Make sure that the camber settings are not disturbed while tightening the nut. Tighten the upper arm inboard nut to 250 Nm (185 ft. lbs.) 5. Recheck the camber settings and adjust as necessary. 6. Check and, if necessary, adjust the rear toe. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations View 151-2 (Engine Compartment - 4.0L, (2 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 6940 C121 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch POWER STEERING PRESSURE (PSP) SWITCH Typical Power Steering Pressure (PSP) Switch The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch > Page 6943 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor POWER STEERING PRESSURE (PSP) SENSOR Typical Power Steering Pressure (PSP) Sensor The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM changes as the hydraulic pressure changes. The PCM uses the input signal from the PSP sensor to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP sensor signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example, during parking maneuvers. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 6947 C226 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 6952 C226 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Special Tool(s) NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the Smart Junction Box (SJB). NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire Pressure Monitoring System (TPMS). Radio frequency noise is generated by electrical motors and appliance operation, cellular telephones, remote transmitters, power inverters and portable entertainment equipment. NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor again. NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire procedure must be repeated. NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for front and rear tires, tire rotation will not affect the system. 1. Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. - The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire Pressure Monitor Activation Tool must remain in place 180 degrees from the valve stem. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 6957 6. Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press and release the test button on the Tire Pressure Monitor Activation Tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB. 7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF tire sidewall opposite (180 degrees) from the valve stem and press and release the test button to train the RF tire pressure sensor. NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and the entire procedure must be repeated. 8. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor identifiers trained to the SJB and document them on the applicable warranty claim. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed SJB. 10. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and carry out the SJB On-Demand Self Test. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Disassembly CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor can be removed and installed without removing the strap or the cradle. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. 1. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. 2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip can occur. Using a pocket screwdriver, or similar tool, remove the sensor locking clip. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 6960 3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor can occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. 4. Remove the sensor. Assembly 1. CAUTION: Damage to the sensor can occur if excessive force is applied during sensor installation. NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise when correctly seated. Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the sensor locking clip cannot be fully inserted, then the sensor may not be fully seated on the cradle or the locking clip may be inserted backward. Insert a new locking clip into the sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 6961 3. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Training. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 6962 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Material Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 6963 Disassembly CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There are several different strap kits available based on wheel diameter but all strap kits share the same base part number. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. 1. Remove the tire pressure monitoring system (TPMS) sensor. 2. WARNING: The TPMS band is under tension. Always use safety goggles or a face shield and gloves when removing the TPMS band/strap. Failure to follow these instructions may result in personal injury. Remove a factory installed strap in this sequence: 1 Locate the strap buckle and secure the strap to the wheel using duct tape or a similar item, on both sides of the buckle approximately 25 mm (0.98 inch) from the buckle. 2 Using a large screwdriver and a twisting motion, unbuckle the strap. 3 Discard the strap. To remove a dealer installed strap, turn the worm gear screw until the strap is fully released from the worm gear. ^ Discard the strap. 3. NOTE: To aid assembly, mark the location of the cradle prior to disassembly. Using a screwdriver, or similar tool, remove the cradle by inserting the screwdriver under the cradle and prying up. Assembly 1. NOTE: Make sure the sensor is fully seated into the new cradle. The sensor will make a "click" noise when fully seated. Position the sensor into the new cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. CAUTION: Metal scrapers can damage the wheel. Use only plastic or non-metallic scrapers to remove the cradle adhesive strip residue. NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the valve stem. Clean the area where the sensor and cradle are to be installed. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 6964 3. NOTE: The sensor and cradle must be positioned with the hinge side of the sensor on the RH side when viewed from the curb side (beauty side) of the wheel. NOTE: The sensor has raised markings indicating how to position the sensor. Remove the adhesive tape liner from the cradle and position the sensor and cradle into the wheel drop well 180° from the valve stem. 4. Install the tapered end of the strap through the opening of the cradle on the hinge side of the sensor. This will position the worm gear on the locking clip side of the sensor. 5. CAUTION: Steel wheels have a "high spot" along their circumference. Make sure the strap is positioned in the lowest spot possible for correct sensor and cradle retention. NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear. Position the worm gear 13 - 26 mm (0.5 - 1.0 inch) away from the sensor and tighten the worm gear. ^ Tighten to 3 Nm (27 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 6965 6. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Training. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair Wheel Knuckle Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Page 6970 Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number or an equivalent part must be installed, if installation is necessary. Do not use a part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Remove the wheel bearing and hub assembly. 2. Remove the wheel speed sensor harness bracket bolt from the wheel knuckle. ^ To install, tighten to 8 Nm (71 inch lbs.) 3. Remove and discard the tie-rod end nut. ^ To install, tighten to 103 Nm (76 ft. lbs.) 4. CAUTION: Do not use a hammer to separate the tie rod from the wheel knuckle or damage to the wheel knuckle can result. CAUTION: Do not damage the tie-rod boot while installing the special tool. Using the special tool, separate the tie-rod end from the wheel knuckle. 5. Remove and discard the lower ball joint nut. ^ To install, tighten to 150 Nm (111 ft. lbs.) 6. CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to the wheel knuckle can result. CAUTION: Do not damage the ball joint boot while installing the special tool. Using the special tool, separate the lower ball joint from the wheel knuckle. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Page 6971 7. Remove and discard the upper ball joint nut. ^ To install, tighten to 55 Nm (41 ft. lbs.) 8. CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to the wheel knuckle can result. CAUTION: Do not damage the ball joint boot while installing the special tool. Using the special tool, separate the upper ball joint and remove the wheel knuckle. 9. To install, reverse the removal procedure. ^ Check and, if necessary, align the front end. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair Power Steering System Purging Special Tool(s) Material CAUTION: If the air is not purged from the power steering system correctly, premature power steering pump failure can 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 can be caused by air in the system. The power steering purge procedure must be carried out prior to any component repair for which power steering noise complaints are accompanied by evidence of aerated fluid. Remove the power steering pump reservoir cap. Check the fluid. 2. Raise the front wheels off the floor. 3. Tightly insert the stopper of the vacuum pump into the reservoir. 4. Start the engine. Install the vacuum pump, apply vacuum and maintain the maximum vacuum of 68 - 85 kPa (20 - 25 in-Hg). 5. If equipped with Hydro-Boost(R), apply the brake pedal twice. 6. CAUTION: Do not hold the steering wheel against the stops for more than 3 to 5 seconds at a time. Damage to the power steering pump can occur. Cycle the steering wheel fully from stop-to-stop 10 times. 7. Stop the engine. 8. Release the vacuum and remove the vacuum pump. 9. CAUTION: Do not overfill the reservoir. Fill the reservoir. ^ Use approved transmission fluid. 10. Start the engine. 11. Install the vacuum pump. Apply and maintain the maximum vacuum of 68 - 85 kPa (20 - 25 in-Hg). 12. CAUTION: Do not hold the steering wheel against the stops for more than 3 to 5 seconds at a time. Damage to the power steering pump can occur. Cycle the steering wheel fully from stop-to-stop 10 times. 13. Stop the engine, release the vacuum and remove the vacuum pump. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 6976 14. CAUTION: Do not overfill the reservoir. Fill the reservoir as needed and install the reservoir cap. 15. Visually inspect the power steering system for leaks. 17. CAUTION: Do not overfill the reservoir. Fill the reservoir as needed and visually inspect the power steering system for leaks. 18. Install the reservoir cap. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 6981 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 6982 Power Steering Fluid: Specifications Power steering fluid ............................................................................................................................. ................................... Motorcraft MERCON ATF Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 6983 Power Steering Fluid: Testing and Inspection Power Steering Fluid Leak Test NOTE: This test should only be carried out if a leak in the system has not been detected during a thorough visual inspection. Refer to Inspection and Verification. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Inspection and Verification 1. Check the power steering fluid level. If necessary, add the specified power steering fluid. 2. Remove the power steering pump reservoir cap and tightly install the evacuation cap to the power steering pump reservoir. 3. Install the hose from the fill adapter manifold tee to the evacuation cap on the power steering pump reservoir. 4. Install the vacuum pump to the evacuation cap. 5. Using the vacuum pump, apply 68 - 85 kPa (20 - 25 in-Hg) of vacuum to the power steering system. 6. Observe the vacuum gauge for 30 seconds. If the vacuum gauge reading drops more than 3 kPa (0.88 in-Hg) a leak is present. 7. Remove the vacuum pump. 8. CAUTION: Do not hold the steering wheel at the stops for more than 3-5 seconds. Damage to the power steering pump can occur. Start the engine. With the engine at idle, raise the power steering fluid temperature to 74 - 80°C (165 - 176°F) by rotating the steering wheel fully to the left and right several times. 9. Visually inspect the system for leaks. If a leak is evident, repair as necessary. If a leak is not evident, add the specified UV fluorescent tracer dye to the power steering fluid. Use 14.78 mL (1/2 oz) of dye solution for every 1.89 L (2 qt) of power steering fluid. 10. CAUTION: Do not hold the steering wheel at the stops for more than 3-5 seconds. Damage to the power steering pump can occur. Start the engine. With the engine at idle, raise the power steering fluid temperature to 74 - 80°C (165 - 176°F) by rotating the steering wheel fully to the left and right several times. 11. NOTE: On vehicles with rack and pinion steering gear, it may be necessary to remove the bellows boot clamp from the steering gear bellows boots to inspect for internal steering gear leaks. Using the special tool (UV lamp), inspect the system for traces of UV dye. Repair as necessary. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair Power Steering Fluid Cooler: Service and Repair Power Steering Fluid Cooler Material Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Page 6987 Removal and Installation Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Page 6988 CAUTION: While repairing the power steering system, care should be taken to prevent the entry of contaminants or premature failure of the power steering components can result. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Release the fluid cooler hose clamp and disconnect the hose from the fluid reservoir. 3. Remove the LH front splash shield screws, pin-type retainers and the splash shield. 4. Remove the lower radiator air deflector pushpins and the air deflector. 5. Remove the 2 fluid cooler hose braces. 6. Remove the fluid cooler hose bracket bolt. ^ To install, tighten to 18 Nm (13 ft. lbs.) 7. Remove the steering line clamp plate nut. ^ To install, tighten to 25 Nm (18 ft. lbs.) 8. Rotate the steering line clamp plate and disconnect the fluid cooler return line from the steering gear. ^ Discard the O-ring seal. 9. Remove the power steering fluid cooler. 10. NOTE: New O-ring seals must be installed whenever the steering lines are disconnected. To install, reverse the removal procedure. ^ Fill the power steering system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair Power Steering Fluid Reservoir: Service and Repair Power Steering Fluid Reservoir Material Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair > Page 6992 Removal and Installation CAUTION: While repairing the power steering system, care should be taken to prevent the entry of contaminants or premature failure of the power steering components can result. 1. Using a suitable suction device, drain the power steering fluid reservoir. 2. Remove the power steering fluid reservoir bolt. ^ To install, tighten to 9 Nm (80 inch lbs.) 3. Release the reservoir-to-pump hose clamp and disconnect the hose. 4. Release the power steering fluid cooler-to-reservoir hose clamp and disconnect the hose. 5. Remove the power steering fluid reservoir. 6. To install, reverse the removal procedure. ^ Fill the power steering system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair Power Steering Line/Hose: Service and Repair Power Steering Pump to Steering Gear Pressure Line Special Tool(s) Material Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Page 6996 Removal CAUTION: While repairing the power steering system, care should be taken to prevent the entry of contaminants or premature failure of the power steering components can result. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove the power steering pump pulley. 3. Remove the steering line clamp plate nut. 4. Rotate the steering line clamp plate and disconnect the fluid cooler return line from the steering gear. ^ Discard the O-ring seal. 5. Disconnect the pressure line from the steering gear. ^ Discard the O-ring seal. 6. Remove the pressure line bracket-to-engine nut (4.6L) or bolt (4.0L). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Page 6997 7. Remove the pressure line-to-crossmember retainer bracket bolt. 8. Disconnect the pressure line-to-pump fitting. ^ Remove and discard the Teflon(R) O-ring seal. 9. Remove the pressure line. Installation 1. NOTE: A new Teflon(R) O-ring seal must be installed. Using the special tool, install a new Teflon(R) O-ring seal on the pressure line fitting. 2. Position the pressure line and connect the pressure line-to-pump fitting. ^ Tighten to 65 Nm (48 ft. lbs.) 3. Install the pressure line bracket-to-engine nut (4.6L) or bolt (4.0L). ^ Tighten to 11 Nm (8 ft. lbs.) 4. NOTE: New O-rings must be installed whenever the power steering lines are disconnected. Install a new O-ring seal and position the pressure line to the steering gear. 5. Install the pressure line bracket-to-crossmember bolt. ^ Tighten to 12 Nm (9 ft. lbs.) 6. Install a new O-ring seal and position the power steering gear-to-fluid cooler return hose to the steering gear. Rotate the steering line clamp plate into position. 7. Install the steering line clamp plate nut. ^ Tighten to 25 Nm (18 ft. lbs.) 8. Install the power steering pump pulley. 9. Fill the power steering system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Power Steering Pump - 4.0L Special Tool(s) Material Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7002 Removal CAUTION: While repairing the power steering system, care should be taken to prevent the entry of contaminants or premature failure of the power steering components can result. 1. Using a suitable suction device, drain the power steering fluid reservoir. 2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 3. Remove the power steering pump pulley. 4. Remove the pressure line bracket-to-engine bolt. 5. Remove the power steering fluid reservoir-to-pump hose bracket bolt. 6. Release the reservoir-to-pump hose clamp and disconnect the hose. 7. Disconnect the pressure line-to-pump fitting. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7003 ^ Remove and discard the Teflon(R) O-ring seal. 8. Remove the 3 bolts and the power steering pump. Installation 1. NOTE: A new Teflon(R) O-ring seal must be installed. Using the special tool, install a new Teflon(R) O-ring seal to the pressure line fitting. 2. Position the power steering pump and install the 3 bolts. ^ Tighten to 25 Nm (18 ft. lbs.) 3. Connect the pressure line-to-pump fitting. ^ Tighten to 65 Nm (48 ft. lbs.) 4. Connect the reservoir-to-pump hose. 5. Install the power steering fluid reservoir-to-pump hose bracket bolt. ^ Tighten to 11 Nm (8 ft. lbs.) 6. Install the pressure line bracket-to-engine bolt. ^ Tighten to 11 Nm (8 ft. lbs.) 7. Install the power steering pump pulley. 8. Fill the power steering system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7004 Power Steering Pump: Service and Repair Power Steering Pump Pulley Power Steering Pump Pulley - 4.0L Power Steering Pump Pulley - 4.0L Removal and Installation 1. Disconnect the fan clutch electrical connector. 2. Remove the fan clutch wiring harness bracket bolt and position harness aside. ^ To install, tighten to 7 Nm (62 inch lbs.) 3. Loosen the 3 power steering pump pulley bolts. 4. Rotate the tensioner and remove the engine accessory drive belt from the power steering pump pulley. 5. Remove the 3 bolts and the power steering pump pulley. ^ To install, tighten to 25 Nm (18 ft. lbs.) 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations View 151-2 (Engine Compartment - 4.0L, (2 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 7009 C121 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch POWER STEERING PRESSURE (PSP) SWITCH Typical Power Steering Pressure (PSP) Switch The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch > Page 7012 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor POWER STEERING PRESSURE (PSP) SENSOR Typical Power Steering Pressure (PSP) Sensor The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM changes as the hydraulic pressure changes. The PCM uses the input signal from the PSP sensor to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP sensor signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example, during parking maneuvers. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 7016 C226 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Locations View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Locations > Page 7020 C226 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Depowering and Repowering SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING Special Tool(s) Special Tool(s) Depowering 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. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the electrical connector on a safety canopy module. Doing so can result in safety canopy deployment. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a SRS component is being serviced, the SRS must be depowered. - 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. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box (SJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse 17 (10A) from the SJB. 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 switch to OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or installing any front or side air bag supplemental restraint system (SRS) components and before servicing, installing, 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 front impact severity sensors are located on the radiator support bracket above the lower front splash shield. The front door side impact sensors are located in the first row doors, behind the door trim panel. The C-pillar side impact sensors (if equipped) are located on the C-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). Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7026 remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install RCM fuse 17 (10A) to the SJB and close the cover. 4. 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. 5. Prove out the SRS as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch 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 6 seconds and then turn off. If an air bag SRS fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag indicator might not light 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 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 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous diagnostic trouble codes (DTCs) from the RCM and occupant classification sensor (OCS) module using a scan tool. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7027 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Deactivation and Reactivation SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION Special Tool(s) Special Tool(s) Deactivation 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. - Never probe the connectors on the safety canopy module. Doing so can result in safety canopy deployment, which can result in personal injury. - The safety belt pretensioner and adaptive load limiting retractor are pyrotechnic devices. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner/adaptive load limiting retractor. Never probe a pretensioner or adaptive load limiting retractor electrical connector. Doing so could result in pretensioner, adaptive load limiting retractor or air bag deployment and could result in personal injury. - 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a SRS component is being serviced, the SRS must be depowered. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7028 - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a SRS fault. - 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 smart junction box (SJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse 17 (10A) from the SJB. 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 front impact severity sensors are located on the radiator support bracket above the lower front splash shield. The front door side impact sensors are located in the first row doors, behind the door trim panel. The C-pillar side impact sensors (if equipped) are located on the C-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). Disconnect the battery ground cable and wait at least one minute. 7. Remove the 2 driver air bag module bolts (1 shown). 8. NOTE: Note the position of the 3 driver air bag module wiring connectors for installation. Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag module. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7029 9. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of the steering column. 10. Open and lower the glove compartment door. 11. Detach the wiring retainer, remove the 4 bolts and the passenger air bag module heat shield. 12. NOTE: Deactivate the passenger air bag module as shown, the canister vent and adaptive tether squibs do not require deactivation. Through the glove compartment opening, disconnect the LH side passenger air bag module electrical connector. 13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector on the LH side. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7030 14. From under the rear of the passenger seat, detach the passenger seat side air bag module electrical connector from the seat track bracket. Then slide and disengage the passenger seat side air bag module electrical connector locking clip, and then release the tab and disconnect the passenger seat side air bag module electrical connector. 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat side air bag module electrical connector. Vehicles without safety canopy modules 16. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy bridge resistor from the safety canopy electrical connector. If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the RCM. If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low resistance fault will be generated by the RCM. Explorer and Mountaineer vehicles with safety canopy modules 17. Release and position aside the passenger side C-pillar trim panel. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7031 18. Disconnect the passenger side safety canopy module electrical connector. 19. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. 20. Release and position aside the driver side C-pillar trim panel. 21. Disconnect the driver side safety canopy module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7032 22. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. Explorer Sport Trac vehicles with safety canopy modules 23. Remove the driver and passenger side upper C-pillar trim panels. 24. Disconnect the passenger side safety canopy module electrical connector. 25. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. 26. Disconnect the driver side safety canopy module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7033 27. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. All vehicles 28. From under the rear of the driver seat, slide and disengage the driver seat side air bag module electrical connector locking clip, and then release the tab and disconnect the driver seat side air bag module electrical connector. 29. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air bag module electrical connector. 30. Install the RCM fuse 17 (10A) to the SJB. 31. Connect the battery ground cable. Reactivation All vehicles 1. Remove the RCM fuse 17 (10A) from the SJB. 2. Disconnect the battery ground cable and wait at least one minute. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7034 3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat side air bag module electrical connector. 4. Connect the driver seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Explorer Sport Trac vehicles with safety canopy modules 5. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 6. Connect the driver side safety canopy module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7035 7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 8. Connect the passenger side safety canopy module electrical connector. 9. Install the driver and passenger upper C-pillar trim panels. Explorer and Mountaineer vehicles with safety canopy modules 10. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 11. Connect the driver side safety canopy module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7036 12. Install the driver side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. 13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 14. Connect the passenger side safety canopy module electrical connector. 15. Install the passenger side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. All vehicles Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7037 16. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat side air bag module electrical connector. 17. Connect the passenger seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Then attach the passenger seat side air bag module electrical connector to the seat track bracket. 18. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector on the LH side. 19. Connect the LH side passenger air bag module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7038 20. Install the passenger air bag module heat shield and the 4 bolts. Attach the wiring retainer. 21. Close glove compartment door. 22. Remove the restraint system diagnostic tools from the clockspring electrical connectors at the top of the steering column. 23. CAUTION: The clockspring electrical connectors are unique and cannot be connected to the driver air bag module in the wrong position. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Connect the driver air bag module electrical connectors as noted in removal. 24. Install the 2 driver air bag module bolts (1 shown). - Tighten to 7 Nm (62 lb-in). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7039 25. 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. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 26. Turn the ignition switch from OFF to ON. 27. Install the RCM fuse 17 (10A) to the SJB and install the cover. 28. 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. 29. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the switch 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 6 seconds and then turn off. If an air bag SRS fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag indicator might not light 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 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 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and occupant classification sensor (OCS) module using a scan tool. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair Steering Column Cover: Service and Repair STEERING COLUMN COVER Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Page 7043 Part 2 Exploded Views Removal and Installation 1. Remove the steering column opening cover. - Remove the 2 screws and remove the cover. 2. Remove the lower and upper steering column covers. - Remove the 2 screws from the lower steering column cover and remove both covers. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Mount > Component Information > Technical Service Bulletins > Recalls for Steering Gear Mount: > NHTSA07V181000 > Apr > 07 > Recall 07V181000: Steering Gear Mounting Bolt Replacment Steering Gear Mount: Recalls Recall 07V181000: Steering Gear Mounting Bolt Replacment MAKE/MODELS: MODEL/BUILD YEARS: Ford/Explorer 2007 Ford/Explorer Sport Trac 2007 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V181000 MFR'S REPORT DATE: April 24, 2007 COMPONENT: Steering POTENTIAL NUMBER OF UNITS AFFECTED: 11 SUMMARY: On certain sport utility vehicles, the two bolts that attach the steering gear assembly to the frame may have been over-tightened. This condition could result in one or both of the bolts fracturing, causing the steering gear to become loose. CONSEQUENCE: This condition could cause "clunking" noise when steering as well as decreased steering effectiveness potentially resulting in a crash. REMEDY: Dealers will replace both the steering gear assembly mounting bolts and nuts free of charge. The recall is expected to begin on or about May 5, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 07S52. Customers may 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Mount > Component Information > Technical Service Bulletins > Recalls for Steering Gear Mount: > 07S52 > Apr > 07 > Recall - Steering Gear Mounting Bolt Replacement Technical Service Bulletin # 07S52 Date: 070419 Attachment I - Administrative Information OASIS ACTIVATED? Yes. OASIS will be activated by April 19, 2007 FSA VIN LIST ACTIVATED? Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Mount > Component Information > Technical Service Bulletins > Recalls for Steering Gear Mount: > 07S52 > Apr > 07 > Recall - Steering Gear Mounting Bolt Replacement > Page 7057 Yes. FSA VIN Lists will be available through the website by April 19, 2007. Owner names and addresses will be available by May 10, 2007. 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 demonstration or 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 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 Refunds are not authorized for this program. RENTAL VEHICLES In situations where the vehicle is in the shop and parts need to be ordered, Ford Motor Company will pay for a rental vehicle, except for fuel and insurance which will be at the owner's expense. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "RENTAL" plus the number of days the vehicle was used in the Miscellaneous Expense area of the recall claim form. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ 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. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires approval from Special Service Support Center. Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Mount > Component Information > Technical Service Bulletins > Recalls for Steering Gear Mount: > 07S52 > Apr > 07 > Recall - Steering Gear Mounting Bolt Replacement > Page 7058 LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. 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 program involves replacing the steering gear bolts and nuts. REPLACEMENT 1. Raise the vehicle on a hoist. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Mount > Component Information > Technical Service Bulletins > Recalls for Steering Gear Mount: > 07S52 > Apr > 07 > Recall - Steering Gear Mounting Bolt Replacement > Page 7059 2. Remove the steering gear bolts and nuts. See Figure 1. 3. Install new steering gear bolts and nuts. 4. Tighten the steering gear bolts to 350 Nm (258 lb-ft). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Mount > Component Information > Technical Service Bulletins > Recalls for Steering Gear Mount: > 07S52 > Apr > 07 > Recall - Steering Gear Mounting Bolt Replacement > Page 7060 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Mount > Component Information > Technical Service Bulletins > Recalls for Steering Gear Mount: > 07S52 > Apr > 07 > Recall - Steering Gear Mounting Bolt Replacement > Page 7061 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear Mount: > NHTSA07V181000 > Apr > 07 > Recall 07V181000: Steering Gear Mounting Bolt Replacment Steering Gear Mount: All Technical Service Bulletins Recall 07V181000: Steering Gear Mounting Bolt Replacment MAKE/MODELS: MODEL/BUILD YEARS: Ford/Explorer 2007 Ford/Explorer Sport Trac 2007 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V181000 MFR'S REPORT DATE: April 24, 2007 COMPONENT: Steering POTENTIAL NUMBER OF UNITS AFFECTED: 11 SUMMARY: On certain sport utility vehicles, the two bolts that attach the steering gear assembly to the frame may have been over-tightened. This condition could result in one or both of the bolts fracturing, causing the steering gear to become loose. CONSEQUENCE: This condition could cause "clunking" noise when steering as well as decreased steering effectiveness potentially resulting in a crash. REMEDY: Dealers will replace both the steering gear assembly mounting bolts and nuts free of charge. The recall is expected to begin on or about May 5, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 07S52. Customers may 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear Mount: > 07S52 > Apr > 07 > Recall - Steering Gear Mounting Bolt Replacement Technical Service Bulletin # 07S52 Date: 070419 Attachment I - Administrative Information OASIS ACTIVATED? Yes. OASIS will be activated by April 19, 2007 FSA VIN LIST ACTIVATED? Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear Mount: > 07S52 > Apr > 07 > Recall - Steering Gear Mounting Bolt Replacement > Page 7071 Yes. FSA VIN Lists will be available through the website by April 19, 2007. Owner names and addresses will be available by May 10, 2007. 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 demonstration or 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 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 Refunds are not authorized for this program. RENTAL VEHICLES In situations where the vehicle is in the shop and parts need to be ordered, Ford Motor Company will pay for a rental vehicle, except for fuel and insurance which will be at the owner's expense. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "RENTAL" plus the number of days the vehicle was used in the Miscellaneous Expense area of the recall claim form. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ 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. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires approval from Special Service Support Center. Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear Mount: > 07S52 > Apr > 07 > Recall - Steering Gear Mounting Bolt Replacement > Page 7072 LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. 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 program involves replacing the steering gear bolts and nuts. REPLACEMENT 1. Raise the vehicle on a hoist. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear Mount: > 07S52 > Apr > 07 > Recall - Steering Gear Mounting Bolt Replacement > Page 7073 2. Remove the steering gear bolts and nuts. See Figure 1. 3. Install new steering gear bolts and nuts. 4. Tighten the steering gear bolts to 350 Nm (258 lb-ft). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear Mount: > 07S52 > Apr > 07 > Recall - Steering Gear Mounting Bolt Replacement > Page 7074 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear Mount: > 07S52 > Apr > 07 > Recall - Steering Gear Mounting Bolt Replacement > Page 7075 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Steering Column Shaft - Upper Steering Shaft: Service and Repair Steering Column Shaft - Upper Steering Column Shaft - Upper Steering Column Shaft - Upper Removal and Installation 1. CAUTION: Do not allow the steering column shaft to rotate while the intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence that the shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to Air Bag Systems. Place the steering wheel and the front wheels in the straight-ahead position. ^ Turn the ignition switch to the OFF position and remove the key. 2. Remove and discard the upper steering column shaft-to-steering column bolt. ^ To install, tighten to 30 Nm (22 ft. lbs.) 3. Remove the 3 upper steering column shaft dash seal bolts. ^ To install, tighten to 12 Nm (9 ft. lbs.) 4. Remove and discard the lower steering column shaft-to-upper steering column shaft bolt. ^ To install, tighten to 47 Nm (35 ft. lbs.) 5. Remove the upper steering column shaft. 6. CAUTION: New steering column shaft bolts must be installed. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Steering Column Shaft - Upper > Page 7080 Steering Shaft: Service and Repair Steering Column Shaft - Lower Steering Column Shaft - Lower Steering Column Shaft - Lower Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. CAUTION: Do not allow the steering column shaft to rotate while the lower shaft is disconnected or damage to the clockspring can result. If there is evidence that the shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to Air Bag Systems. Place the steering wheel and the front wheels in the straight-ahead position. ^ Turn the ignition switch to the OFF position and remove the key. 3. Remove and discard the lower steering column shaft-to-steering column shaft bolt. ^ To install, tighten to 47 Nm (35 ft. lbs.) 4. Remove and discard the lower steering column shaft-to-steering gear bolt. ^ To install, tighten to 47 Nm (35 ft. lbs.) 5. Remove the lower steering column shaft. 6. Inspect the lower steering column shaft for boot damage or separation from the shaft tube. ^ If damage or separation of the lower steering column shaft is evident, install a new lower steering column shaft. 7. CAUTION: New steering column shaft bolts must be installed. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 (V6-4.0L VIN K (2007)) 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 7089 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 (V6-4.0L VIN K (2007)) 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 (V6-4.0L VIN K (2007)) 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 7095 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 7096 View 151-30 (Steering Wheel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 7097 C203 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 7098 Steering Wheel: Service and Repair Steering Wheel Steering Wheel Removal and Installation 1. Place the steering wheel in the straight-ahead position and turn the ignition switch to the OFF position. 2. Remove the driver air bag module. For additional information, refer to Air Bag Systems. 3. Disconnect the steering wheel switches electrical connector. 4. NOTE: A new bolt must be installed. Remove the steering wheel bolt and the steering wheel. ^ Discard the bolt. ^ To install, tighten to 40 Nm (30 ft. lbs.) 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair Tie Rod: Service and Repair Inner Tie Rod Special Tool(s) Material Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Page 7102 Removal CAUTION: The boots and clamps are designed to provide an airtight seal and protect the internal components of the steering gear. If the seal is not airtight the vacuum generated during turning will draw water and contamination into the gear causing premature damage. CAUTION: Zip ties do not produce an airtight seal and must not be used. CAUTION: The inner ball joint grease is not compatible with water and contamination trapped in the grease will degrade the life of the joint. CAUTION: If present, the orientation of the vent tube must be noted so the boots and vent tubes can be installed in the correct location. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Loosen the tie-rod end jam nut. 3. Remove and discard the tie-rod end nut. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Page 7103 4. CAUTION: Do not damage the tie-rod boot when installing the special tool. Using the special tool, separate the tie-rod end from the wheel knuckle. 5. NOTE: Count the number of turns required to remove the tie-rod end for reference during installation. Remove the tie-rod end. 6. Remove the tie-rod end jam nut. 7. NOTE: A new outer bellows boot clamp must be installed. Remove and discard the outer bellows boot clamp. 8. NOTE: A new inner bellows boot clamp must be installed. Remove and discard the inner bellows boot clamp. 9. Remove the steering gear bellows boot. 10. CAUTION: Place the steering gear at the center position. Use a 1-1/16 inch crowfoot on the flat of the rack gear to resist rotation and to prevent damage during removal and installation of the inner tie rod. NOTE: If repairing the RH side, it will be necessary to pull back the LH inner tie-rod boot to hold the steering gear. NOTE: An assistant may be needed for removal of the RH inner tie rod. Using the special tool, remove the inner tie rod. 11. CAUTION: Thoroughly remove any abrasive material. This material is extremely harmful to the steering gear. Thoroughly clean and inspect all the parts to be reused. Install new parts as necessary. Installation 1. Using the special tool, install the inner tie rod. ^ Tighten to 100 Nm (74 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Page 7104 2. NOTE: Apply steering gear grease to the steering gear bellows boot groove in the inner tie rod. NOTE: Make sure the steering gear bellows boot is positioned correctly over the steering gear housing bead and the groove in the inner tie rod. NOTE: Make sure the steering gear bellows boot is not twisted and the vent tube (if equipped) is securely inserted into the vent nipple of the steering gear bellows boot. Install the steering gear bellows boot. Using the special tool, install a new inner bellows boot clamp. 13. NOTE: Make sure the end of the steering gear bellows is positioned between the 2 grooves on the inner tie rod or an internal leak can result. Install a new outer bellows boot clamp. 14. Thread the tie-rod end jam nut onto the inner tie rod. 15. NOTE: Install the tie-rod end the same number of turns as recorded during the removal. Install the tie-rod end to the inner tie rod. 16. Tighten the tie-rod end jam nut. ^ Tighten to 80 Nm (59 ft. lbs.) 8. Position the tie-rod end to the wheel knuckle and install a new tie-rod end nut. ^ Tighten to 103 Nm (76 ft. lbs.) 9. Check and, if necessary, align the front end. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications Ball Joint: Specifications Ball Joint Deflection Lower ................................................................................................................................................... ........................................ 0-0.8 mm (0-0.032 inch) Upper .................................................................. ......................................................................................................................... 0-0.2 mm (0-0.008 inch) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 7109 Ball Joint: Testing and Inspection Ball Joint Inspection 1. Prior to inspecting the ball joints for wear, inspect the wheel bearings. For additional information, refer to Vehicle/Testing and Inspection. 2. NOTE: In order to obtain an accurate measurement, the suspension must be in full rebound with the weight of the vehicle supported by the frame. Raise and support the vehicle by the frame to allow the wheels to hang in the rebound position. 3. Inspect the ball joint and ball joint boot for damage. ^ If the ball joint or ball joint boot is damaged, install a new ball joint as necessary. NOTE: Carry out Steps 4-6 to inspect the lower ball joint. Carry out Steps 7-9 to inspect the upper ball joint. 4. CAUTION: Do not use any tools or equipment to move the wheel and tire assembly or suspension components while checking for relative movement or suspension damage can occur. The use of tools or equipment will also create relative movement that may not exist when using hand force. Relative movement must be measured using hand force only. NOTE: The weight of the wheel and tire assembly must be overcome to obtain an accurate measurement on the dial indicator. Inspect the ball joint for relative movement by alternately pulling downward and pushing upward on the wheel and tire assembly by hand. Note any relative vertical movement between the wheel knuckle and lower arm at the lower ball joint. ^ If relative movement is not felt or seen, the ball joint is OK. Do not install a new ball joint. ^ If relative movement is found, continue with Step 5. 5. NOTE: In order to obtain an accurate measurement, the dial indicator should be aligned as close as possible with the vertical axis (center line) of the ball joint. To measure ball joint deflection, attach a suitable dial indicator with a flexible arm between the lower control arm and the wheel knuckle or ball joint stud. 6. Measure the ball joint deflection while an assistant pushes up and pulls down on the wheel and tire assembly, by hand. ^ If the deflection exceeds the specification, a new ball joint must be installed. ^ If the deflection meets the specification, continue with the procedure. 7. CAUTION: Do not use any tools or equipment to move the wheel and tire assembly or suspension components while checking for relative movement or suspension damage can occur. The use of tools or equipment will also create relative movement that may not exist when using hand force. Relative movement must be measured using hand force only. Inspect the ball joint for relative movement by alternately pulling downward and pushing upward on the upper control arm by hand. Note any relative vertical movement between the wheel knuckle and upper arm at the upper ball joint. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 7110 ^ If relative movement is not felt or seen, the ball joint is OK. Do not install a new ball joint. ^ If relative movement is found, continue with Step 8. 8. NOTE: In order to obtain an accurate measurement, the dial indicator should be aligned as close as possible with the vertical axis of the ball joint. To measure ball joint deflection, attach a suitable dial indicator with a flexible arm between the upper control arm and the wheel knuckle or ball joint stud. ^ If the deflection meets the specification, no further action is required. 9. Measure the ball joint deflection while an assistant pushes up and then pulls down on the upper control arm, by hand. ^ If the deflection exceeds the specification, a new ball joint must be installed. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Control Arm: Service and Repair Front Lower Arm Lower Arm Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 7115 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 7116 Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number or an equivalent part must be installed, if installation is necessary. Do not use a part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Measure the distance from the center of the hub to the lip of the fender with the vehicle in a level, static ground position (curb height). 2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 3. Remove and discard the lower ball joint nut. ^ To install, tighten to 150 Nm (111 ft. lbs.) 4. CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to the wheel knuckle can result. CAUTION: Do not damage the ball joint boot while installing the special tool. Using the special tool, separate the lower ball joint from the wheel knuckle. 5. Remove and discard the stabilizer bar link nut. ^ To install, tighten to 35 Nm (26 ft. lbs.) at curb height. 6. Remove the stabilizer bar link assembly. 7. Remove and discard the shock absorber lower bolt and flag nut and bolt. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 7117 ^ To install, tighten to 350 Nm (258 ft. lbs.) at curb height. 8. Remove and discard the lower arm forward nut and bolt. ^ To install, tighten to 400 Nm (296 ft. lbs.) at curb height. 9. Remove the lower arm rearward nut and bolt and the lower control arm. ^ Discard the nut and bolt. ^ To install, tighten to 200 Nm (148 ft. lbs.) at curb height. 10. CAUTION: Before tightening any suspension bushing fasteners, use a suitable jack to raise the suspension until the distance between the center of the hub and the lip of the fender is equal to the measurement taken in Step 1 (curb height). To install, reverse the removal procedure. ^ Check and, if necessary, align the front end. Upper Arm Upper Arm Special Tool(s) Removal and Installation Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 7118 CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number or an equivalent part must be installed, if installation is necessary. Do not use a part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Measure the distance from the center of the hub to the lip of the fender with the vehicle in a level, static ground position (curb height). 2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 3. Using a suitable jack support the lower control arm near the lower ball joint. 4. Remove and discard the upper ball joint nut. ^ To install, tighten to 55 Nm (41 ft. lbs.) 5. CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to the wheel knuckle can result. CAUTION: Do not damage the ball joint boot while installing the special tool. Using the special tool, separate the upper ball joint from the wheel knuckle. 6. Using a plastic tie strap, support the suspension at the wheel knuckle. 7. Remove the 2 upper arm bolts and flag nuts and the upper arm. ^ To install, tighten to 150 Nm (111 ft. lbs.) at curb height. 8. CAUTION: Before tightening any suspension bushing fasteners, use a suitable jack to raise the suspension until the distance between the center of the hub and the lip of the fender is equal to the measurement taken in Step 1 (curb height). To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 7119 ^ Check and, if necessary, align the front end. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 7120 Control Arm: Service and Repair Rear Upper Arm Upper Arm Upper Arm Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. CAUTION: Orientation of the suspension fasteners is important. Make sure the fasteners are installed in the same direction as they were in when removed. 1. Measure the distance from the center of the hub to the lip of the fender with the vehicle in a level, static ground position (curb height). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 7121 2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 3. Position a suitable jack under the wheel knuckle and raise the suspension until the distance between the center of the hub and the lip of the fender is equal to the measurement taken in Step 1. 4. Remove and discard the upper arm outboard nut and bolt. 5. NOTE: The inboard nut that is installed at the assembly plant is a flag nut. This flag nut is used to set and maintain the rear camber settings. Discard the flag nut and install a non-flag nut to allow the rear camber to be adjusted. Remove and discard the upper arm inboard bolt and flag nut and remove the upper arm. Installation 1. Position the upper arm and install a new inboard bolt and non-flag nut. ^ Tighten to 250 Nm (185 ft. lbs.) 2. CAUTION: The upper arm outboard bolt must be installed with the bolt head toward the front of the vehicle or wheel damage can occur. Install a new outboard bolt and nut with the bolt head toward the front of the vehicle. ^ Tighten to 275 Nm (203 ft. lbs.) 3. Lower the suspension and remove the jack. 4. Check and, if necessary, align the rear end. Lower Arm Lower Arm Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 7122 Lower Arm Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. CAUTION: Orientation of the suspension fasteners is important. Make sure the fasteners are installed in the same direction as they were in when removed. 1. Measure the distance from the center of the hub to the lip of the fender with the vehicle in a level, static ground position (curb height). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 7123 2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 3. Position a suitable jack under the wheel knuckle and raise the suspension until the distance between the center of the hub and the lip of the fender is equal to the measurement taken in Step 1. 4. Remove and discard the lower arm outboard bolt and flag nut. 5. Remove the stabilizer bar link nut and grommet, stud and link assembly. ^ Discard the nut and grommet. 6. Lower the suspension and remove the jack. 7. Remove and discard the shock absorber lower nut and bolt. 8. Remove and discard the lower arm inboard nut and bolt and remove the lower arm. Installation 1. CAUTION: Do not tighten the lower arm inboard nut at this time. Position the lower arm and install a new lower arm inboard bolt and nut. 2. CAUTION: Do not tighten the shock absorber lower nut at this time. Position the lower arm and install a new shock absorber lower bolt and nut. 3. Position a suitable jack under the wheel knuckle and raise the suspension until the distance between the center of the hub and the lip of the fender is equal to the measurement taken in Step 1. 4. Install the stabilizer link assembly, the link stud and a new nut and grommet. ^ Tighten to 30 Nm (22 ft. lbs.) 5. Install a new lower arm outboard bolt and flag nut. ^ Tighten the bolt to 275 Nm (203 ft. lbs.) 6. Tighten the lower arm inboard bolt to 250 Nm (185 ft. lbs.) 7. Tighten the shock absorber lower bolt to 275 Nm (203 ft. lbs.) 8. Lower the suspension and remove the jack. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Crossmember - 1B Rear Cross-Member: Service and Repair Crossmember - 1B CROSSMEMBER - 1B Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 4 crossmember bolts. 3. Remove the 4 crossmember nuts. - To install, tighten to 103 Nm (76 lb-ft). 4. Remove the 1B crossmember. 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Crossmember - 1B > Page 7129 Rear Cross-Member: Service and Repair Transmission Support Crossmember TRANSMISSION SUPPORT CROSSMEMBER Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 4 transfer case skid plate bolts and remove the transfer case skid plate. - To install, tighten to 15 Nm (11 lb-ft). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Crossmember - 1B > Page 7130 3. NOTE: Explorer/Mountaineer shown, Explorer Sport Trac similar. Remove the heat shield bolt from the RH heat shield. To install, tighten to 18 Nm (13 lb-ft). 4. Remove the heat shield bolt from the LH heat shield. - To install, tighten to 18 Nm (13 lb-ft). 5. Support the transmission with a suitable jack. 6. Remove the 2 transmission mount nuts. - To install, tighten to 90 Nm (66 lb-ft). 7. Remove the 6 transmission crossmember lower bolts. - To install, tighten to 80 Nm (59 lb-ft). 8. NOTE: Tighten the nut side of the joint. Remove the 2 upper nuts and 2 bolts from the transmission crossmember. To install, tighten to 143 Nm (105 lb-ft). 9. Remove the transmission crossmember. 10. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair Wheel Knuckle Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Page 7134 Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number or an equivalent part must be installed, if installation is necessary. Do not use a part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Remove the wheel bearing and hub assembly. 2. Remove the wheel speed sensor harness bracket bolt from the wheel knuckle. ^ To install, tighten to 8 Nm (71 inch lbs.) 3. Remove and discard the tie-rod end nut. ^ To install, tighten to 103 Nm (76 ft. lbs.) 4. CAUTION: Do not use a hammer to separate the tie rod from the wheel knuckle or damage to the wheel knuckle can result. CAUTION: Do not damage the tie-rod boot while installing the special tool. Using the special tool, separate the tie-rod end from the wheel knuckle. 5. Remove and discard the lower ball joint nut. ^ To install, tighten to 150 Nm (111 ft. lbs.) 6. CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to the wheel knuckle can result. CAUTION: Do not damage the ball joint boot while installing the special tool. Using the special tool, separate the lower ball joint from the wheel knuckle. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Page 7135 7. Remove and discard the upper ball joint nut. ^ To install, tighten to 55 Nm (41 ft. lbs.) 8. CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to the wheel knuckle can result. CAUTION: Do not damage the ball joint boot while installing the special tool. Using the special tool, separate the upper ball joint and remove the wheel knuckle. 9. To install, reverse the removal procedure. ^ Check and, if necessary, align the front end. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair Rear Knuckle: Service and Repair Wheel Knuckle Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 7139 Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. CAUTION: Orientation of the suspension fasteners is important. Make sure the fasteners are installed in the same direction as they were in when removed. 1. Measure the distance from the center of the hub to the lip of the fender with the vehicle in a level, static ground position (curb height). 2. If equipped, remove the wheel speed sensor bolt and position the sensor aside. 3. CAUTION: Do not loosen the halfshaft nut and washer until the wheel and tire are removed from the vehicle. Wheel bearing damage Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 7140 will occur if the wheel bearing is unloaded with the weight of the vehicle applied. NOTE: Apply the brake to keep the halfshaft from rotating. Remove and discard the front wheel hub nut. 4. Remove the parking brake shoes. 5. CAUTION: Do not use a hammer to separate the halfshaft from the hub. Damage to the threads and internal constant velocity (CV) joint components can result. Using the special tool, press the halfshaft from the hub. 6. Position a suitable jack under the wheel knuckle and raise the suspension until the distance between the center of the hub and the lip of the fender is equal to the measurement taken in Step 1. 7. Remove and discard the toe link outboard nut and bolt. 8. Remove and discard the upper arm outboard nut and bolt. 9. Remove and discard the lower arm outboard nut and bolt. 10. Remove and discard the 3 wheel knuckle bolts and remove the wheel knuckle. 11. If a new wheel knuckle is being installed, remove the wheel bearing and wheel hub. Installation 1. Position the wheel knuckle and install 3 new wheel knuckle bolts. ^ Tighten to 275 Nm (203 ft. lbs.) 2. Install a new lower arm outboard bolt and flag nut. ^ Tighten to 275 Nm (203 ft. lbs.) 3. CAUTION: The upper arm outboard bolt must be installed with the bolt head toward the front of the vehicle or wheel damage can occur. Install a new upper arm outboard bolt and nut with the bolt head toward the front of the vehicle. ^ Tighten to 275 Nm (203 ft. lbs.) 4. Position the toe link and install a new toe link outboard bolt and nut. ^ Tighten to 350 Nm (259 ft. lbs.) 5. Lower the suspension and remove the jack. 6. Install the parking brake shoes. 7. Position the wheel speed sensor and install the bolt. ^ Tighten to 8 Nm (71 inch lbs.) 8. Using a suitable halfshaft installer tool, install the halfshaft. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 7141 9. NOTE: Have an assistant press the brake pedal to keep the axle from turning. Install a new halfshaft nut and washer. ^ Tighten to 275 Nm (203 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Toe Link Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. CAUTION: Orientation of the suspension fasteners is important. Make sure the fasteners are installed in the same direction as they were in when removed. 1. Measure the distance from the center of the hub to the lip of the fender with the vehicle in a level, static ground position (curb height). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle Alignment Link > Component Information > Service and Repair > Page 7145 2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 3. Position a suitable jack under the wheel knuckle and raise the suspension until the distance between the center of the hub and the lip of the fender is equal to the measurement taken in Step 1. 4. Index-mark the toe link cam bolt to the subframe. 5. Remove the toe link cam adjuster nut, cam adjuster and cam bolt. ^ Discard the nut. 6. Remove and discard the toe link outboard nut and bolt and remove the toe link. Installation 1. Position the toe link and install a new outboard bolt and nut. ^ Tighten to 350 Nm (259 ft. lbs.) 2. NOTE: Do not tighten the cam adjuster nut at this time. Install the toe link cam bolt, cam adjuster and a new nut. 3. NOTE: Make sure the cam bolt and the adjustment cam are seated between the offsets before tightening the nut. Align the index mark on the cam bolt with the index mark on the subframe and tighten the nut. ^ Tighten to 275 Nm (203 ft. lbs.) 4. Lower the suspension and remove the jack. 5. Check and, if necessary, adjust the rear toe. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 7150 C226 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Stabilizer Link: Service and Repair Front Stabilizer Bar and Link Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number or an equivalent part must be installed, if installation is necessary. Do not use a part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. Remove and discard the 2 stabilizer bar nuts and grommets. ^ To install, tighten to 35 Nm (26 ft. lbs.) at curb height. 3. Remove and discard the 2 stabilizer bar studs. 4. Remove the 2 stabilizer bar links. 5. NOTE: Inspect and clean the mating surfaces and the internal threads. Make sure all mating surfaces are free of foreign material and remove any Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front > Page 7156 thread locking compound from the internal threads. NOTE: Rotate the stabilizer bar and pull outward to remove. Remove the 4 stabilizer bar bracket bolts and the stabilizer bar, and the brackets and bushings. ^ Discard the bolts. ^ To install, tighten to 55 Nm (41 ft. lbs.) at curb height. 6. NOTE: When installing the sway bar bushings onto the sway bar, match the groove in the bushing to the upset on the sway bar. NOTE: Inspect the stabilizer bar bushings for wear or damage. Install new bushings as necessary. NOTE: Tighten LH side first. Remove the 2 stabilizer bar bushings. 7. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front > Page 7157 Stabilizer Link: Service and Repair Rear Stabilizer Bar and Link - Explorer, Mountaineer Stabilizer Bar and Link - Explorer, Mountaineer Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. CAUTION: Orientation of the suspension fasteners is important. Make sure the fasteners are installed in the same direction as they were in when removed. 1. Measure the distance from the center of the hub to the lip of the fender with the vehicle in a level, static ground position (curb height). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front > Page 7158 2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 3. CAUTION: The upper arm outboard bolt must be installed with the bolt head toward the front of the vehicle or wheel damage can occur. Remove and discard the outboard nut and bolt from both upper arms. ^ To install, tighten to 275 Nm (203 ft. lbs.) at curb height. 4. Remove the stabilizer bar link nut and grommet, stud and link assembly. ^ Discard the nut and grommet. ^ To install, tighten to 30 Nm (22 ft. lbs.) at curb height. 5. Remove and discard the 4 stabilizer bar bracket nuts. ^ To install, tighten to 48 Nm (35 ft. lbs.) 6. Remove the 2 stabilizer bar brackets and the 2 stabilizer bar bushings. 7. Remove the 4 stabilizer bar bracket studs. ^ For the front studs, push the stud down and slide the stud toward the rear of the vehicle. ^ For the rear studs, push the stud down and slide the stud toward the front of the vehicle. 8. Disconnect the fuel vapor line. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front > Page 7159 9. Unclip the fuel vapor line from the fuel tank and position aside. 10. CAUTION: Extreme care must be exercised when removing and installing the stabilizer bar on vehicles equipped with rear air conditioning (A/C) and/or rear heating or damage to the A/C lines and rear heater hoses can occur. With the aid of an assistant, remove the stabilizer bar from the LH side of the vehicle. 11. CAUTION: Before tightening the stabilizer bar link nuts, use a suitable jack to raise the suspension until the distance between the center of the hub and the lip of the fender is equal to the measurement taken in Step 1 (curb height). To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal and Replacement Suspension Spring ( Coil / Leaf ): Removal and Replacement Shock Absorber and Spring Assembly Shock Absorber and Spring Assembly Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Remove the lower arm. 2. Remove and discard the 3 shock absorber upper mount nuts and remove the shock absorber and spring assembly. ^ To install, tighten to 30 Nm (22 ft. lbs.) 3. For additional information on the disassembly and assembly of the shock absorber and spring assembly, refer to Shock Absorber and Spring Assembly. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal and Replacement > Page 7164 Suspension Spring ( Coil / Leaf ): Overhaul Front Shock Absorber and Spring Assembly Shock Absorber and Spring Assembly Disassembly and Assembly WARNING: All vehicles are equipped with gas-pressurized shock absorbers which will extend unassisted. Do not apply heat or flame to the shock absorbers during removal or component servicing. Failure to follow these instructions may result in personal injury. CAUTION: suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number or an equivalent part must be installed, if installation is necessary. Do not use a part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal and Replacement > Page 7165 1. Remove the shock absorber and spring assembly. 2. Using a suitable spring compressor, compress the spring until the tension is released from the shock absorber. 3. CAUTION: Use the holding feature to prevent the shock absorber rod from turning while removing and installing the nut. CAUTION: When installing the shock rod nut, make sure the shock rod and bushing are centered in the upper mount before tightening the nut. Remove and discard the shock absorber rod nut. ^ To install, tighten to 65 Nm (48 ft. lbs.) 4. Remove the shock absorber. 5. Remove the washer and upper mount bushing. 6. Remove the upper shock absorber mount. 7. Remove the dust boot. 8. Carefully release the spring compressor and remove the coil spring. 9. NOTE: When installing the shock rod nut, make sure the shock rod and bushing are centered in the upper mount before tightening the nut. NOTE: Make sure that the upper shock mount stud, shock rod and shock lower bushing are aligned before tightening shock absorber rod nut. To assemble, reverse the disassembly procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal and Replacement > Page 7166 Rear Shock Absorber and Spring Assembly Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal and Replacement > Page 7167 Disassembly and Assembly 1. Remove the shock absorber and spring assembly. 2. Using a suitable spring compressor, compress the spring until the tension is released from the shock absorber. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal and Replacement > Page 7168 3. CAUTION: Use the holding feature to prevent the shock absorber rod from turning while removing and installing the nut. CAUTION: When installing the shock rod nut, make sure the shock rod and bushing are centered in the upper mount before tightening the nut. Remove and discard the shock absorber rod nut. ^ To install, tighten to 65 Nm (48 ft. lbs.) 4. Remove the shock absorber. 5. Remove the shock absorber upper mount. 6. Remove the upper mount bushing. 7. Carefully release the spring compressor and remove the coil spring. 8. NOTE: Make sure the upper shock mount stud, shock rod and shock lower bushing are aligned before tightening the shock rod nut. To assemble, reverse the disassembly procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal and Replacement > Page 7169 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement Suspension Strut / Shock Absorber: Removal and Replacement Front Suspension Shock Absorber and Spring Assembly Special Tool(s) Removal and Installation WARNING: All vehicles are equipped with gas-pressurized shock absorbers which will extend unassisted. Do not apply heat or flame to the shock absorbers during removal or component servicing. Failure to follow these instructions may result in personal injury. CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number or an equivalent part must be installed, if installation is necessary. Do not use a part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 7174 retention of these parts. 1. Measure the distance from the center of the hub to the lip of the fender with the vehicle in a level, static ground position (curb height). 2. Remove and discard the 3 shock absorber upper mount nuts. ^ To install, tighten to 30 Nm (22 ft. lbs.) at curb height. 3. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 4. Using a suitable jack, support the lower control arm near the lower ball joint. 5. Remove and discard the stabilizer bar link nut and grommet and then remove the stabilizer bar link assembly. ^ To install, tighten to 35 Nm (26 ft. lbs.) at curb height. 6. Remove the shock absorber lower bolt and flag nut. ^ Discard the lower shock bolt and flag nut. ^ To install, tighten to 350 Nm (258 ft. lbs.) at curb height. 7. Remove and discard the upper ball joint nut. ^ To install, tighten to 55 Nm (41 ft. lbs.) 8. CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to the wheel knuckle can result. CAUTION: Do not damage the ball joint boot while installing the special tool. Using the special tool, separate the upper ball joint from the wheel knuckle. 9. While lowering the suspension, remove the shock and spring assembly. 10. CAUTION: Before tightening any suspension bushing fasteners, use a suitable jack to raise the suspension until the distance between the center of the hub and the lip of the fender is equal to the measurement taken in Step 1 (curb height). To install, reverse the removal procedure. Rear Suspension Shock Absorber and Spring Assembly Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 7175 Shock Absorber and Spring Assembly Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Remove the lower arm. 2. Remove and discard the 3 shock absorber upper mount nuts and remove the shock absorber and spring assembly. ^ To install, tighten to 30 Nm (22 ft. lbs.) 3. For additional information on the disassembly and assembly of the shock absorber and spring assembly, refer to Shock Absorber and Spring Assembly. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 7176 Suspension Strut / Shock Absorber: Overhaul Front Shock Absorber and Spring Assembly Shock Absorber and Spring Assembly Disassembly and Assembly WARNING: All vehicles are equipped with gas-pressurized shock absorbers which will extend unassisted. Do not apply heat or flame to the shock absorbers during removal or component servicing. Failure to follow these instructions may result in personal injury. CAUTION: suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number or an equivalent part must be installed, if installation is necessary. Do not use a part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 7177 1. Remove the shock absorber and spring assembly. 2. Using a suitable spring compressor, compress the spring until the tension is released from the shock absorber. 3. CAUTION: Use the holding feature to prevent the shock absorber rod from turning while removing and installing the nut. CAUTION: When installing the shock rod nut, make sure the shock rod and bushing are centered in the upper mount before tightening the nut. Remove and discard the shock absorber rod nut. ^ To install, tighten to 65 Nm (48 ft. lbs.) 4. Remove the shock absorber. 5. Remove the washer and upper mount bushing. 6. Remove the upper shock absorber mount. 7. Remove the dust boot. 8. Carefully release the spring compressor and remove the coil spring. 9. NOTE: When installing the shock rod nut, make sure the shock rod and bushing are centered in the upper mount before tightening the nut. NOTE: Make sure that the upper shock mount stud, shock rod and shock lower bushing are aligned before tightening shock absorber rod nut. To assemble, reverse the disassembly procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 7178 Rear Shock Absorber and Spring Assembly Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 7179 Disassembly and Assembly 1. Remove the shock absorber and spring assembly. 2. Using a suitable spring compressor, compress the spring until the tension is released from the shock absorber. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 7180 3. CAUTION: Use the holding feature to prevent the shock absorber rod from turning while removing and installing the nut. CAUTION: When installing the shock rod nut, make sure the shock rod and bushing are centered in the upper mount before tightening the nut. Remove and discard the shock absorber rod nut. ^ To install, tighten to 65 Nm (48 ft. lbs.) 4. Remove the shock absorber. 5. Remove the shock absorber upper mount. 6. Remove the upper mount bushing. 7. Carefully release the spring compressor and remove the coil spring. 8. NOTE: Make sure the upper shock mount stud, shock rod and shock lower bushing are aligned before tightening the shock rod nut. To assemble, reverse the disassembly procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 7181 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair Trailing Arm: Service and Repair Trailing Arm Trailing Arm Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. CAUTION: Orientation of the suspension fasteners is important. Make sure the fasteners are installed in the same direction as they were in Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair > Page 7185 when removed. 1. Remove the toe link. 2. Remove the parking brake cable bracket bolt. ^ To install, tighten to 10 Nm (89 inch lbs.) 3. Remove and discard the trailing arm bolt. ^ To install, tighten to 300 Nm (222 ft. lbs.) at curb height. 4. Remove the 3 wheel knuckle bolts and the trailing arm. ^ Discard the bolts. ^ To install, tighten to 275 Nm (203 ft. lbs.) 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Wheel Bearing and Wheel Hub Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number or an equivalent part must be installed, if installation is necessary. Do not use a part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose can occur. Remove the bolts and position the caliper, pads and anchor plate assembly aside. ^ Discard the bolts. ^ Support the caliper and anchor plate assembly using mechanic's wire. ^ To install, tighten to 165 Nm (122 ft. lbs.) 3. Remove the brake disc. 4. CAUTION: Inspect and if necessary, clean area around wheel speed sensor before removing it from the wheel bearing and hub. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 7190 Remove the wheel speed sensor bolt and disconnect the wheel speed sensor from the wheel bearing and hub assembly. ^ To install, tighten to 18 Nm (13 ft. lbs.) 5. Remove the 3 bolts and the wheel bearing and hub assembly. ^ Discard the bolts. ^ To install, tighten to 122 Nm (90 ft. lbs.) 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 7191 Wheel Bearing: Service and Repair Rear Wheel Bearing and Wheel Hub Special Tool(s) Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Remove the wheel knuckle. 2. Remove the 3 brake disc shield bolts. ^ To install, tighten to 8 Nm (71 inch lbs.) 3. Using the special tool and a suitable press, remove the wheel hub. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 7192 4. Remove the snap ring. 5. Using a suitable press and adapters, remove the wheel bearing. 6. To install, reverse the removal procedure. 7. Install the wheel knuckle. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Testing and Inspection > Driveline System Wheel Hub: Testing and Inspection Driveline System Inspection and Verification Certain axle and driveline symptoms are also common to the engine, transmission, wheel bearings, tires and other parts of the vehicle. For this reason, be sure that the cause of the concern is in the axle before disassembling, adjusting or repairing the axle. Refer to Vehicle/Testing and Inspection. Certain driveshaft vibration symptoms are common to the front engine accessory drive (FEAD), the engine, transmission or tires. Be sure the cause of the concern is the driveshaft before repairing or installing a new driveshaft. Refer to Vehicle/Testing and Inspection. Noise Acceptability A gear-driven unit will produce a certain amount of noise. Some noise is acceptable and audible at certain speeds or under various driving conditions, such as a newly paved blacktop road. Slight noise is not detrimental to the operation of the axle and is considered normal. Universal Joint (U-Joint) Inspection Place the vehicle on a frame hoist and rotate the driveshaft by hand. Check for rough operation or seized U-joints. Install a new U-joint if it shows signs of seizure, excessive wear or incorrect seating. Analysis of Leakage Clean up the leaking area enough to identify the exact source. An axle leak can be caused by: ^ Axle lubricant level is too high ^ Worn or damaged axle shaft seals or differential seals ^ Differential housing is cracked ^ Flange yoke seal is worn or damaged ^ Pinion flange is scored or damaged ^ Axle cover is not sealed ^ Vent is plugged Repair the axle as necessary. Make sure the axle lubricant is at the correct level. Axle Vent NOTE: If a plugged vent cannot be cleared, install a new vent. NOTE: If the vent is removed from the housing for any reason, a new vent must be installed. A plugged vent will cause excessive seal lip wear due to internal pressure buildup. If a leak occurs, check the vent. Make sure the vent hose is not kinked. Remove the hose from the vent nipple and clear the hose of any foreign material. While the hose is removed, pass a length of mechanic's wire or a small diameter Allen wrench in and out of the vent to clean it. Connect the hose when done. Flange Yoke Seal Leaks at the axle drive pinion seal originate for these reasons: ^ The seal is not correctly installed ^ A poor quality seal journal surface Any damage to the seal bore (dings, dents, gouges or other imperfections) will distort the seal casing and allow leakage past the outer edge of the axle drive pinion seal. The axle drive pinion seal can be torn, cut or gouged if it is not installed carefully. The spring that holds the axle drive pinion seal against the pinion flange can be knocked out, which can allow leakage past the lip. The rubber lips can occasionally become hard (like plastic) with cracks at the oil lip contact point. The contact point on the pinion flange may blacken, indicating excessive heat. Marks, nicks, gouges or rough surface texture on the seal journal of the pinion flange will also cause leaks. A new pinion flange must be installed if any of these conditions exist. Metal chips or sand trapped at the sealing lip can also cause oil leaks. This can cause a wear groove on the pinion flange and heavy pinion seal wear. When a seal leak occurs, install a new seal and check the vent and the vent hose to make sure they are clean and free of foreign material. Analysis of Vibration WARNING: An all-wheel drive (AWD) vehicle will always have all wheels (on both axles) driving. If only one wheel/axle is raised off the floor and the axle is driven by the engine, the wheel/axle on the floor could drive the vehicle off the stand or jack. Be sure all wheels are off the floor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Testing and Inspection > Driveline System > Page 7197 Few vibration conditions are caused by the front or rear axle. For a vibration concern, follow the diagnosis procedure in Vehicle/Testing and Inspection unless there is a good reason to suspect the axle. Tires WARNING: Do not balance the wheels and tires while they are mounted on the vehicle. Possible tire disintegration or differential failure could result, causing personal injury or extensive component damage. Use an off-vehicle wheel and tire balancer only. Most vibration is caused by tires, driveline angle or driveline imbalance. Vibration is a concern with modern, high-mileage tires if they are not "true" both radially and laterally. They are more susceptible to vibration around the limits of radial and lateral runout of the tire and wheel assembly. They also require more accurate balancing. Wheel and tire runout checks, truing and balancing are normally done before axle inspection. Driveline Imbalance Driveline imbalance can be caused by excessive looseness in the driveshaft, damaged driveshaft tubing, looseness or high runout at the driveshaft attachments (axle and transfer case flanges). Excessive looseness in the driveshaft can be caused by CV joint or universal joint wear, as well as loose fitting slip-yoke splines. Inspect and install new driveshaft components as necessary. Driveline Angle Driveline Angle Driveline angularity is the angular relationship between the engine crankshaft, the driveshaft and the rear axle pinion. Some of the factors determining driveline angularity include ride height, rear spring and engine mounts. An incorrect driveline (pinion) angle can often be detected by examining the driving condition in which the vibration occurs. ^ A vibration during coastdown, from 72 to 56 km/h (45 to 35 mph), is often caused by an excessive U-joint angle at the axle (pinion nose downward). ^ A vibration during acceleration, from 56 to 72 km/h (35 to 45 mph), may indicate an excessive U-joint angle at the axle (pinion nose upward). When these conditions exist, check the driveline angles. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Testing and Inspection > Driveline System > Page 7198 Universal Joint (U-Joint) Wear Place the vehicle on a frame hoist and rotate the driveshaft by hand. Check for rough operation or seized U-joints. Install a new U-joint if it shows signs of seizure, excessive wear or incorrect seating. Wheel Hub Bolt Circle Runout NOTE: The brake discs must be removed to carry out all runout measurements. 1. Position the special tool on the wheel hub bolt, as close to the hub face as possible. Zero the indicator to allow the pointer to deflect either way. 2. Rotate the hub until the next bolt is contacted. Record the measurement and continue until each bolt is checked. The difference between the maximum and minimum contact readings will be the total wheel hub bolt circle runout. The runout must not exceed 0.38 mm (0.015 inch). Pilot Runout 1. Position the special tools on the pilot, as close to the hub as possible. Zero the indicator to allow the pointer to deflect either way. 2. Rotate the hub one full turn and note the maximum and minimum readings. The difference between the maximum and minimum readings will be the total pilot runout. Pilot runout must not exceed 0.15 mm (0.006 inch). Wheel Hub Runout 1. Position the special tool on the wheel hub, as close to the outer edge as possible. Zero the indicator to allow the pointer to deflect either way. 2. Rotate the hub one full turn and note the maximum and minimum readings. The difference between the maximum and minimum readings will be the total wheel hub runout. The runout must not exceed 0.127 mm (0.005 inch). Drive Pinion Stem and Pinion Flange Check the pinion flange runout when all other checks have failed to show the cause of the vibration. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Testing and Inspection > Driveline System > Page 7199 One cause of excessive pinion flange runout is incorrect installation of the axle drive pinion seal. Check to determine if the spring on the seal lip has been dislodged. Halfshafts NOTE: Constant velocity (CV) joints must not be installed unless disassembly and inspection reveals unusual wear. NOTE: While inspecting the boots, watch for indentations ("dimples") in the boot convolutions. Indentations must be removed. ^ Inspect the boots for evidence of cracks, tears or splits. ^ Inspect the underbody for any indication of grease splatter near the boots outboard and inboard locations. This is an indication of boot/clamp damage. Axle Noise NOTE: Before disassembling the axle to diagnose and correct gear noise, eliminate the tires, exhaust, trim items, roof racks and wheel bearings as possible causes. Follow the diagnostic procedures in Vehicle/Testing and Inspection. The noises described as follows usually have specific causes that can be diagnosed by observation as the unit is disassembled. The initial clues are the type of noise heard during the road test. Gear Howl and Whine Howling or whining of the ring gear and pinion is due to an incorrect gear pattern, gear damage or incorrect bearing preload. Bearing Whine Bearing whine is a high-pitched sound similar to a whistle. It is usually caused by worn/damaged pinion bearings, which are operating at driveshaft speed. Bearing noise occurs at all driving speeds. This distinguishes it from gear whine which usually comes and goes as speed changes. As noted, pinion bearings make a high-pitched, whistling noise, usually at all speeds. If however there is only one pinion bearing that is worn/damaged, the noise may vary in different driving phases. New pinion bearings must not be installed unless they are scored or damaged, or there is a specific pinion bearing noise. A worn/damaged bearing will normally be obvious at disassembly. Examine the large end of the rollers for wear. If the pinion bearings original blend radius has worn to a sharp edge, a new pinion bearing must be installed. A wheel bearing noise can be mistaken for a pinion bearing noise. On rear wheel drive (RWD) vehicles, check the wheel bearing for a spalled cup and spalled/damaged rollers. Install a new wheel bearing if any of these concerns are detected. On four wheel drive (4WD) vehicles, check the wheel bearing for rotating smoothness and end play. Chuckle Chuckle that occurs on the coast driving phase is usually caused by excessive clearance between the differential gear hub and the differential case bore. Damage to a gear tooth on the coast side can cause a noise identical to a chuckle. A very small tooth nick or ridge on the edge of a tooth can cause the noise. Clean the gear tooth nick or ridge with a small grinding wheel. If the damaged area is larger than 3.2 mm (1/8 inch), install a new gearset. To check the ring gear and pinion, remove as much lubricant as possible from the gears with clean solvent. Wipe the gears dry or blow them dry with compressed air. Look for scored or damaged teeth. Also look for cracks or other damage. If either gear is scored or damaged badly, a new ring gear and pinion must be installed. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Testing and Inspection > Driveline System > Page 7200 If metal has broken loose, the axle housing must be cleaned to remove particles that will cause damage. At this time, any other damaged parts in the axle housing must also be installed new. Knock Knock, which can occur in all driving phases, has several causes including damaged teeth or gearset. 1. NOTE: Measure the end play with a Dial Indicator with Bracketry and not by feel. Knock is also caused by excessive end play in the axle shafts. Up to 0.762 mm (0.030 inch) is allowed in semi-float axles. The frequency of the knock will be less because the axle shaft speed is slower than the driveshaft. Clunk Clunk is a metallic noise heard when the automatic transmission is engaged in REVERSE or DRIVE. The noise can also occur when throttle is applied or released. It is caused by backlash somewhere in the driveline or loose suspension components; it is felt or heard in the axle. Additionally, clunk may be heard upon initial drive-away. This occurs as engine torque shifts vehicle weight, forcing changes in driveline angles which prevent the driveshaft slip-yoke from sliding on the output shaft. To correct this condition, lubricate the slip-yoke splines. Bearing Rumble Bearing rumble sounds like marbles being tumbled. This condition is usually caused by a worn/damaged wheel bearing. The lower pitch is because the wheel bearing turns at only about 1/3 of the driveshaft speed. Wheel bearing noise also may be high-pitched, similar to gear noise, but will be evident in all 4 driving modes. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Testing and Inspection > Driveline System > Page 7201 Wheel Hub: Testing and Inspection Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear Inspection and Verification Special Tool(s) Material The technician should have a thorough knowledge of driveline system operation and accepted general driveline guidelines to detect any problems. A gear driven unit will produce a certain amount of noise. Some noise is acceptable and audible at certain speeds or under various driving conditions. Certain conditions, such as road conditions and weather, will amplify normal vehicle noise. Certain rear axle and driveline concern symptoms are also common to the engine, transmission, rear wheel bearings and tire. For this reason, be sure the cause of the concern is in the axle before repairing or installing any axle components. This is a guide to diagnose a driveline concern: ^ Verify and document the customer concern. ^ Carry out a preliminary investigation. ^ Road test the vehicle. ^ Find the cause of the problem. ^ Inspect the components. 1. Verify and document the customer concern. 1 When was it first noticed? 2 Did it appear suddenly or gradually? 3 Did anything unusual occur that would coincide with it or precede it? 4 Has the driveline system been repaired before or new components installed? ^ Check the vehicle service record. Note any repairs other than driveline, such as brakes or suspension. 5 Are there any special conditions that will affect the concern or will alter the concern? For example, ^ road speed. ^ type of road. ^ drive mode. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Testing and Inspection > Driveline System > Page 7202 ^ temperature. ^ vehicle loaded or unloaded. 6 Is the condition constant or intermittent? Can the concern be duplicated at any time? 7 Check for TSBs. 2. NOTE: If the inspection reveals an obvious concern, repair the vehicle. Do a preliminary investigation. Visually inspect for obvious signs of damage. 1 Inspect the driveshaft: ^ for build up of any foreign material. ^ for damage, such as a bent tube or missing weights. ^ U-joints, CV joints or flex couplers for wear or damage. 2 Inspect the axle: ^ for signs of leakage at the drain or fill plug, differential seal, vent or halfshaft seals. a plugged vent or vent tube will cause a leak. ^ for damage, such as cracks, bent halfshafts or dented rear cover. ^ for missing fasteners. 3 Inspect other suspect components/systems: ^ inspect the suspension for broken springs, damaged shock absorbers and worn suspension bushings. ^ inspect the rear brake components - lines, cables and calipers. ^ inspect the tires; are they in good condition and do they match? 3. NOTE: A road test is necessary for any customer concern of noise or vibration. Road test the vehicle. 1 During the road test, use these driving methods to diagnose the problem. Is the concern most noticeable: ^ from a stop? ^ on shifts from REVERSE to DRIVE? ^ on turns? sweeping type turn. - tight turn (to the stop). ^ in DRIVE? accelerating the vehicle, definite throttle depression, applying engine torque. ^ in CRUISE? - maintaining a constant speed with the throttle applied. ^ in COAST? decelerating with the throttle closed. 2 Record when the concern occurs. Write down the kph (mph) range at which the noise/vibration occurs. 4. Find the cause of the problem. 1 Compare the inspection and road test results with the chart. 2 Use this diagnostic routine chart to identify the probable cause and know what corrective actions should be taken to repair the component/vehicle and to prevent a reoccurrence. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Testing and Inspection > Driveline System > Page 7203 Diagnostic Routine Chart 5. NOTE: If the conclusion of the road test points to an axle assembly section (ring and pinion or differential case) concern, carry out a visual inspection of the rear axle. Inspect the axle components. 1 Remove the axle assembly. 2 Remove the differential housing cover. Drain the axle lubricant through a white cloth. Check the fluid for: ^ any foreign material. ^ metal particles. ^ burnt odor. 3 NOTE: When inspecting the axle, do not clean the components immediately. Cleaning may remove diagnostic evidence. Inspect the axle components. ^ Look for: loose fasteners. - notches or visible steps or grooves created by wear. - pitting or cracking along gear contact lines. - scuffing or deformations. - discolorations. - nicks or ridges on gear teeth. ^ Clean the axle components for inspection. Remove as much lubricant as possible with clean solvent. Wipe the components or blow them dry with compressed air. ^ Re-inspect for: Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Testing and Inspection > Driveline System > Page 7204 - loose fasteners. - notches or visible steps or grooves created by wear. - pitting or cracking along gear contact lines. - scuffing or deformations. - discolorations. - nicks or ridges on gear teeth. ^ Check backlash and carry out a ring and pinion pattern test. See: Transmission and Drivetrain/Differential Assembly/Testing and Inspection/Component Tests and General Diagnostics/Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear/Checking Tooth Contact Pattern and Condition of The Ring and Pinion Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Service and Repair > Front Wheel Hub: Service and Repair Front Wheel Bearing and Wheel Hub Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number or an equivalent part must be installed, if installation is necessary. Do not use a part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose can occur. Remove the bolts and position the caliper, pads and anchor plate assembly aside. ^ Discard the bolts. ^ Support the caliper and anchor plate assembly using mechanic's wire. ^ To install, tighten to 165 Nm (122 ft. lbs.) 3. Remove the brake disc. 4. CAUTION: Inspect and if necessary, clean area around wheel speed sensor before removing it from the wheel bearing and hub. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Service and Repair > Front > Page 7207 Remove the wheel speed sensor bolt and disconnect the wheel speed sensor from the wheel bearing and hub assembly. ^ To install, tighten to 18 Nm (13 ft. lbs.) 5. Remove the 3 bolts and the wheel bearing and hub assembly. ^ Discard the bolts. ^ To install, tighten to 122 Nm (90 ft. lbs.) 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Service and Repair > Front > Page 7208 Wheel Hub: Service and Repair Rear Wheel Bearing and Wheel Hub Special Tool(s) Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Remove the wheel knuckle. 2. Remove the 3 brake disc shield bolts. ^ To install, tighten to 8 Nm (71 inch lbs.) 3. Using the special tool and a suitable press, remove the wheel hub. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Service and Repair > Front > Page 7209 4. Remove the snap ring. 5. Using a suitable press and adapters, remove the wheel bearing. 6. To install, reverse the removal procedure. 7. Install the wheel knuckle. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation JACKING WARNING: - 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 correctly located to prevent the vehicle from falling. CAUTION: - A wheel chock should be used to prevent the vehicle from rolling and falling off the jack. - Position the jack to avoid contact with the fuel tank. The following offers general guidelines for vehicle jacking. Additionally, jack manufacturers offer their own operating precautions. Be sure to read and understand operating instructions for the jacking equipment before use. Jacking Points NOTE: Place a wheel chock diagonally opposite of the wheel to be raised. The front jacking points are indicated by a cut-out in the frame, located behind the front tire and wheel. CAUTION: Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and adjoining differential housing Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 7214 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. The rear jacking points are indicated by a cut-out in the frame in front of the rear tire and wheel. LIFTING Lifting Points 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. - 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. - Position the hoist adapters to avoid contact with the fuel tank. - To avoid damage to the suspension, do not position the hoist adapters on the rear trailing arm brackets. NOTE: Explorer shown, Explorer Sport Trac similar. The following offers general guidelines for vehicle lifting. Additionally, hoist manufacturers offer their own operating precautions. Be sure to read and understand operating instructions for the lifting equipment before use. Position the hoist directly under the frame rails. Position the hoist directly under the frame rails. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Special Tool(s) NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the Smart Junction Box (SJB). NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire Pressure Monitoring System (TPMS). Radio frequency noise is generated by electrical motors and appliance operation, cellular telephones, remote transmitters, power inverters and portable entertainment equipment. NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor again. NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire procedure must be repeated. NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for front and rear tires, tire rotation will not affect the system. 1. Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. - The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire Pressure Monitor Activation Tool must remain in place 180 degrees from the valve stem. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 7219 6. Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press and release the test button on the Tire Pressure Monitor Activation Tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB. 7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF tire sidewall opposite (180 degrees) from the valve stem and press and release the test button to train the RF tire pressure sensor. NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and the entire procedure must be repeated. 8. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor identifiers trained to the SJB and document them on the applicable warranty claim. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed SJB. 10. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and carry out the SJB On-Demand Self Test. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Disassembly CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor can be removed and installed without removing the strap or the cradle. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. 1. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. 2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip can occur. Using a pocket screwdriver, or similar tool, remove the sensor locking clip. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7222 3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor can occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. 4. Remove the sensor. Assembly 1. CAUTION: Damage to the sensor can occur if excessive force is applied during sensor installation. NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise when correctly seated. Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the sensor locking clip cannot be fully inserted, then the sensor may not be fully seated on the cradle or the locking clip may be inserted backward. Insert a new locking clip into the sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7223 3. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Training. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7224 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Material Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7225 Disassembly CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There are several different strap kits available based on wheel diameter but all strap kits share the same base part number. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. 1. Remove the tire pressure monitoring system (TPMS) sensor. 2. WARNING: The TPMS band is under tension. Always use safety goggles or a face shield and gloves when removing the TPMS band/strap. Failure to follow these instructions may result in personal injury. Remove a factory installed strap in this sequence: 1 Locate the strap buckle and secure the strap to the wheel using duct tape or a similar item, on both sides of the buckle approximately 25 mm (0.98 inch) from the buckle. 2 Using a large screwdriver and a twisting motion, unbuckle the strap. 3 Discard the strap. To remove a dealer installed strap, turn the worm gear screw until the strap is fully released from the worm gear. ^ Discard the strap. 3. NOTE: To aid assembly, mark the location of the cradle prior to disassembly. Using a screwdriver, or similar tool, remove the cradle by inserting the screwdriver under the cradle and prying up. Assembly 1. NOTE: Make sure the sensor is fully seated into the new cradle. The sensor will make a "click" noise when fully seated. Position the sensor into the new cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. CAUTION: Metal scrapers can damage the wheel. Use only plastic or non-metallic scrapers to remove the cradle adhesive strip residue. NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the valve stem. Clean the area where the sensor and cradle are to be installed. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7226 3. NOTE: The sensor and cradle must be positioned with the hinge side of the sensor on the RH side when viewed from the curb side (beauty side) of the wheel. NOTE: The sensor has raised markings indicating how to position the sensor. Remove the adhesive tape liner from the cradle and position the sensor and cradle into the wheel drop well 180° from the valve stem. 4. Install the tapered end of the strap through the opening of the cradle on the hinge side of the sensor. This will position the worm gear on the locking clip side of the sensor. 5. CAUTION: Steel wheels have a "high spot" along their circumference. Make sure the strap is positioned in the lowest spot possible for correct sensor and cradle retention. NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear. Position the worm gear 13 - 26 mm (0.5 - 1.0 inch) away from the sensor and tighten the worm gear. ^ Tighten to 3 Nm (27 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7227 6. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Training. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Testing and Inspection Low Tire Pressure Indicator: Testing and Inspection TPMS Indicator and Message Center Messages The TPMS indicator and vehicle message center (if equipped) sometimes displays faults that cannot be resolved by the customer. Treat these messages as TPMS faults that must be serviced. TPMS Indicator Illuminates Continuously NOTE: If the spare tire is in use, the damaged road tire must be repaired and installed on the vehicle to restore complete TPMS functionality before carrying out any diagnosis. 1. The TPMS indicator remains on continuously for this condition: ^ Low Tire Pressure - The TPMS indicator is illuminated solid and the message center displays LOW TIRE PRESSURE (if equipped). This is displayed when any of the tire pressures are low. When this condition exists, the tire pressure must be adjusted to the recommended cold pressure as indicated on the vehicle certification label. 2. NOTE: The TPMS sensors do not transmit when the vehicle is stationary. If the vehicle has been stationary for more than 30 minutes, it will be necessary to wake up the sensors so they will transmit the latest tire pressure information to the SJB. If the vehicle has been stationary for more than 30 minutes, carry out this procedure to wake up the TPMS sensors. 1 Turn the ignition switch to the ON position. 2 Adjust the air pressure in the LF tire. 3 Activate the LF TPMS sensor, at least 2 times, using the tire pressure monitor activation tool. 4 Repeat Steps 2 and 3 for the remaining tires. 5 If the TPMS indicator remains illuminated after adjusting and activating each sensor, GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures TPMS Indicator Flashes The TPMS indicator flashes for 70 seconds and then remains ON solid when the ignition key is turned to the ON position for these conditions: 1. Tire Pressure Sensor Fault - If equipped, the message center will display TIRE SENSOR FAULT when a tire pressure sensor is malfunctioning. GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures 2. No communication with the SJB (TPMS is integral to the SJB) - The TPMS indicator is illuminated when the instrument cluster has received no signals from the SJB for more than 5 seconds. If equipped, the message center displays TIRE MONITOR FAULT. GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures 3. Tire Pressure Monitor Fault - If equipped, the message center will display TIRE MONITOR FAULT when the tire pressure monitoring system is malfunctioning or communication with the instrument cluster has been lost. GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Special Tool(s) NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the Smart Junction Box (SJB). NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire Pressure Monitoring System (TPMS). Radio frequency noise is generated by electrical motors and appliance operation, cellular telephones, remote transmitters, power inverters and portable entertainment equipment. NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor again. NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire procedure must be repeated. NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for front and rear tires, tire rotation will not affect the system. 1. Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. - The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire Pressure Monitor Activation Tool must remain in place 180 degrees from the valve stem. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 7235 6. Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press and release the test button on the Tire Pressure Monitor Activation Tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB. 7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF tire sidewall opposite (180 degrees) from the valve stem and press and release the test button to train the RF tire pressure sensor. NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and the entire procedure must be repeated. 8. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor identifiers trained to the SJB and document them on the applicable warranty claim. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed SJB. 10. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and carry out the SJB On-Demand Self Test. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Disassembly CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor can be removed and installed without removing the strap or the cradle. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. 1. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. 2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip can occur. Using a pocket screwdriver, or similar tool, remove the sensor locking clip. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7238 3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor can occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. 4. Remove the sensor. Assembly 1. CAUTION: Damage to the sensor can occur if excessive force is applied during sensor installation. NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise when correctly seated. Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the sensor locking clip cannot be fully inserted, then the sensor may not be fully seated on the cradle or the locking clip may be inserted backward. Insert a new locking clip into the sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7239 3. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Training. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7240 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Material Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7241 Disassembly CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There are several different strap kits available based on wheel diameter but all strap kits share the same base part number. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. 1. Remove the tire pressure monitoring system (TPMS) sensor. 2. WARNING: The TPMS band is under tension. Always use safety goggles or a face shield and gloves when removing the TPMS band/strap. Failure to follow these instructions may result in personal injury. Remove a factory installed strap in this sequence: 1 Locate the strap buckle and secure the strap to the wheel using duct tape or a similar item, on both sides of the buckle approximately 25 mm (0.98 inch) from the buckle. 2 Using a large screwdriver and a twisting motion, unbuckle the strap. 3 Discard the strap. To remove a dealer installed strap, turn the worm gear screw until the strap is fully released from the worm gear. ^ Discard the strap. 3. NOTE: To aid assembly, mark the location of the cradle prior to disassembly. Using a screwdriver, or similar tool, remove the cradle by inserting the screwdriver under the cradle and prying up. Assembly 1. NOTE: Make sure the sensor is fully seated into the new cradle. The sensor will make a "click" noise when fully seated. Position the sensor into the new cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. CAUTION: Metal scrapers can damage the wheel. Use only plastic or non-metallic scrapers to remove the cradle adhesive strip residue. NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the valve stem. Clean the area where the sensor and cradle are to be installed. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7242 3. NOTE: The sensor and cradle must be positioned with the hinge side of the sensor on the RH side when viewed from the curb side (beauty side) of the wheel. NOTE: The sensor has raised markings indicating how to position the sensor. Remove the adhesive tape liner from the cradle and position the sensor and cradle into the wheel drop well 180° from the valve stem. 4. Install the tapered end of the strap through the opening of the cradle on the hinge side of the sensor. This will position the worm gear on the locking clip side of the sensor. 5. CAUTION: Steel wheels have a "high spot" along their circumference. Make sure the strap is positioned in the lowest spot possible for correct sensor and cradle retention. NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear. Position the worm gear 13 - 26 mm (0.5 - 1.0 inch) away from the sensor and tighten the worm gear. ^ Tighten to 3 Nm (27 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7243 6. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Training. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 09-14-1 > Jul > 09 > Wheels - 17 Inch Polished Wheel Clearcoat Cracking Wheels: Customer Interest Wheels - 17 Inch Polished Wheel Clearcoat Cracking TSB 09-14-1 07/27/09 17 INCH BRIGHT MACHINED WHEEL - CORROSION AND ETCHING FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles and equipped with 17 inch aluminum wheels may exhibit the clear coat peeling off the wheel or cracks in the clear coat that look like spider webs. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Please review the illustrations of an affected wheel. (Figures 1 and 2) 2. To service, replace only affected wheel or wheels. Refer to Workshop Manual, Section 204-04 for wheel removal and installation procedures including tire pressure monitoring system (TPMS) sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 09-14-1 > Jul > 09 > Wheels - 17 Inch Polished Wheel Clearcoat Cracking > Page 7252 Parts Block 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 091401A 2006-2010 Explorer, 0.6 Hr. Mountaineer, 2007-2010 Explorer Sport Trac: Replace One (1) wheel Includes Time To Transfer TPMS, And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1) 091401B 2006-2010 Explorer, 0.8 Hr. Mountaineer, 2007-2010 Explorer Sport Trac: Replace Two (2) Wheels Includes Time To Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 091401C 2006-2010 Explorer, 1.1 Hrs. Mountaineer, 2007-2010 Explorer Sport Trac: Replace Three (3) Wheels Includes Time To Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 091401D 2006-2010 Explorer, 1.3 Hrs. Mountaineer, 2007-2010 Explorer Sport Trac: Replace Four (4) Wheels Includes Time To Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) DEALER CODING CONDITION BASIC PART NO. CODE 1007 91 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At Low Speeds Wheels: Customer Interest Wheels/Tires - Popping/Snapping Noise At Low Speeds TSB 09-11-2 06/15/09 POPPING/SNAPPING NOISE - FRONT OR REAR 18 INCH WHEELS - TURNING AT SLOW SPEED BELOW 10 MPH (16 KM/H) FORD: 2007-2008 Edge, Explorer Sport Trac, Explorer LINCOLN: 2007-2008 MKX MERCURY: 2007-2008 Mountaineer This article supersedes TSB 09-4-3 to update the vehicle model years. ISSUE Some 2007-2008 Explorer, Sport Trac, and Mountaineer vehicles built prior to 1/28/2008 and 2007-2008 Edge and MKX vehicles built prior to 8/18/2008 and equipped with 18 inch wheels may exhibit a noise coming from the front or rear wheel(s) while turning the steering wheel at speeds lower than 10 MPH (16 Km/h). The noise may be coming from the chrome cladding that attaches to the rim. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IF THE SOURCE OF NOISE IS NOT FROM THE WHEEL, FOLLOW NORMAL WORKSHOP MANUAL PROCEDURES. 1. Verify the noise is coming from the wheel(s). 2. Replace the wheel(s) that have the noise with updated service parts. Refer to Workshop Manual (WSM), Section 204-04. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At Low Speeds > Page 7257 3. Lubricate the remaining wheels at the outboard wheel flange, between the cladding and the wheel inter[ace. Use Motorcraft(R) Silicone Spray Lubricant with an extension nozzle. (Figures 1 and 2) 4. Clean any excess lubricant off the wheel with a soft cloth. Parts Block 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 091102A 2007-2008 Explorer, 0.9 Hr. Explorer Sport Trac, Mountaineer, 2007 Edge, MKX: Replace One Wheel and Lubricate Remaining Three Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1) 091102B 2007-2008 Explorer, 1.1 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge, MKX: Replace Two Wheels and Lubricate Remaining Two Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 091102C 2007-2008 Explorer, 1.4 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge, Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At Low Speeds > Page 7258 MKX: Replace Three Wheels and Lubricate Remaining Wheel. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), Balance And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 091102D 2007-2008 Explorer, 1.6 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge, MKX: Replace Four Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) DEALER CODING CONDITION BASIC PART NO. CODE 1007 68 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels When Turning Wheels: Customer Interest Wheels/Tires - Popping Noise From Wheels When Turning TSB 07-23-4 11/26/07 POPPING/SNAPPING NOISE - FRONT OR REAR 18 INCH WHEELS - TURNING AT SLOW SPEEDS BELOW 10 MPH (16KM/H) FORD: 2007 Edge 2007-2008 Explorer Sport Trac, Explorer MERCURY: 2007-2008 Mountaineer This article supersedes TSB 07-19-6 to update the vehicle lines. ISSUE Some 2007-2008 Explorer, Explorer Sport Trac and Mountaineer vehicles built prior to 8/17/2007 and 2007 Edge vehicles built prior to 8/24/2007 and equipped with 18" wheels may exhibit noise coming from the front or rear wheel(s) while turning the steering wheel at speeds lower than 10 MPH (16 Km/h). The noise may be coming from the chrome cladding that attaches to the rim. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IF THE SOURCE OF NOISE IS NOT FROM THE WHEEL, FOLLOW NORMAL WORKSHOP MANUAL PROCEDURES. 1. Verify the noise is coming from the wheel(s). 2. Replace wheel(s) with updated service parts for 18" Chrome (Bright) Clad Cast Aluminum wheel and Satin Clad Cast Aluminum wheel(s). Refer to Workshop Manual (WSM), Section 204-04. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels When Turning > Page 7263 3. Lubricate the remaining wheels at the outboard wheel flange, between the cladding and the wheel inter[ace. Use Motorcraft Silicone Spray Lubricant and spray lubricant with an extension nozzle. (Figures 1 and 2) NOTE NEW WHEELS WILL NOT REQUIRE LUBRICATION. 4. Clean any excess lubricate off the wheel with a soft cloth. 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 072304A 2007-2008 Explorer, 0.9 Hr. Explorer Sport Trac, Mountaineer, 2007 Edge: Replace One Wheel and Lubricate Remaining Three Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1) 072304B 2007-2008 Explorer, 1.1 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge: Replace Two Wheels and Lubricate Remaining Two Wheels. Includes Test Drive, Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 072304C 2007-2008 Explorer, 1.4 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge: Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels When Turning > Page 7264 Replace Three Wheels and Lubricate Remaining Wheel. Includes Test Drive, Transfer TPMS, Balance And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 072304D 2007-2008 Explorer, 1.6 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge: Replace Four Wheels. Includes Test Drive, Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) DEALER CODING CONDITION BASIC PART NO. CODE 1007 68 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 07-12-2 > Jun > 07 > Wheels - 16 Inch Wheel Clear Coat Peeling/Cracking Wheels: Customer Interest Wheels - 16 Inch Wheel Clear Coat Peeling/Cracking TSB 07-12-2 06/25/07 16 INCH BRIGHT MACHINED WHEEL-CORROSION AND ETCHING FORD: 2006-2007 Explorer 2007 Explorer Sport Trac ISSUE Some 2006-2007 Explorer and 2007 Explorer Sport Trac vehicles equipped with 16 inch wheels may exhibit the clear coat peeling off the wheel or cracks in the clear coat that look like spider webs. ACTION Replace affected wheel or wheels with new wheels that have added corrosion protection. SERVICE PROCEDURE Please review illustration shown below. To service, replace only affected wheel or wheels. Refer to Workshop Manual Section 204-04 for wheel removal and installation procedures. See example of affected wheel in Figure 1. Parts Block 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 071202A 2006-2007 Explorer, 2007 0.5 Hr. Explorer Sport Trac: Replace One Wheel, Includes Time To Transfer Tire Pressure Monitor Sensor (TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1, 1552A, 1007D3) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 07-12-2 > Jun > 07 > Wheels - 16 Inch Wheel Clear Coat Peeling/Cracking > Page 7269 071202B 2006-2007 Explorer, 2007 0.7 Hr. Explorer Sport Trac: Replace Two Wheels, Includes Time To Transfer Tire Pressure Monitor Sensor (TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1, 1552A, 1007D3) 071202C 2006-2007 Explorer, 2007 1.0 Hr. Explorer Sport Trac: Replace Three Wheels, Includes Time To Transfer Tire Pressure Monitor Sensor (TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1, 1552A, 1007D3) 071202D 2006-2007 Explorer, 2007 1.2 Hrs. Explorer Sport Trac: Replace All Wheels, Includes Time To Transfer Tire Pressure Monitor Sensor (TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1, 1552A, 1007D3) DEALER CODING CONDITION BASIC PART NO. CODE 1007 D4 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 09-14-1 > Jul > 09 > Wheels - 17 Inch Polished Wheel Clearcoat Cracking Wheels: All Technical Service Bulletins Wheels - 17 Inch Polished Wheel Clearcoat Cracking TSB 09-14-1 07/27/09 17 INCH BRIGHT MACHINED WHEEL - CORROSION AND ETCHING FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles and equipped with 17 inch aluminum wheels may exhibit the clear coat peeling off the wheel or cracks in the clear coat that look like spider webs. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Please review the illustrations of an affected wheel. (Figures 1 and 2) 2. To service, replace only affected wheel or wheels. Refer to Workshop Manual, Section 204-04 for wheel removal and installation procedures including tire pressure monitoring system (TPMS) sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 09-14-1 > Jul > 09 > Wheels - 17 Inch Polished Wheel Clearcoat Cracking > Page 7275 Parts Block 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 091401A 2006-2010 Explorer, 0.6 Hr. Mountaineer, 2007-2010 Explorer Sport Trac: Replace One (1) wheel Includes Time To Transfer TPMS, And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1) 091401B 2006-2010 Explorer, 0.8 Hr. Mountaineer, 2007-2010 Explorer Sport Trac: Replace Two (2) Wheels Includes Time To Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 091401C 2006-2010 Explorer, 1.1 Hrs. Mountaineer, 2007-2010 Explorer Sport Trac: Replace Three (3) Wheels Includes Time To Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 091401D 2006-2010 Explorer, 1.3 Hrs. Mountaineer, 2007-2010 Explorer Sport Trac: Replace Four (4) Wheels Includes Time To Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) DEALER CODING CONDITION BASIC PART NO. CODE 1007 91 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At Low Speeds Wheels: All Technical Service Bulletins Wheels/Tires - Popping/Snapping Noise At Low Speeds TSB 09-11-2 06/15/09 POPPING/SNAPPING NOISE - FRONT OR REAR 18 INCH WHEELS - TURNING AT SLOW SPEED BELOW 10 MPH (16 KM/H) FORD: 2007-2008 Edge, Explorer Sport Trac, Explorer LINCOLN: 2007-2008 MKX MERCURY: 2007-2008 Mountaineer This article supersedes TSB 09-4-3 to update the vehicle model years. ISSUE Some 2007-2008 Explorer, Sport Trac, and Mountaineer vehicles built prior to 1/28/2008 and 2007-2008 Edge and MKX vehicles built prior to 8/18/2008 and equipped with 18 inch wheels may exhibit a noise coming from the front or rear wheel(s) while turning the steering wheel at speeds lower than 10 MPH (16 Km/h). The noise may be coming from the chrome cladding that attaches to the rim. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IF THE SOURCE OF NOISE IS NOT FROM THE WHEEL, FOLLOW NORMAL WORKSHOP MANUAL PROCEDURES. 1. Verify the noise is coming from the wheel(s). 2. Replace the wheel(s) that have the noise with updated service parts. Refer to Workshop Manual (WSM), Section 204-04. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At Low Speeds > Page 7280 3. Lubricate the remaining wheels at the outboard wheel flange, between the cladding and the wheel inter[ace. Use Motorcraft(R) Silicone Spray Lubricant with an extension nozzle. (Figures 1 and 2) 4. Clean any excess lubricant off the wheel with a soft cloth. Parts Block 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 091102A 2007-2008 Explorer, 0.9 Hr. Explorer Sport Trac, Mountaineer, 2007 Edge, MKX: Replace One Wheel and Lubricate Remaining Three Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1) 091102B 2007-2008 Explorer, 1.1 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge, MKX: Replace Two Wheels and Lubricate Remaining Two Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 091102C 2007-2008 Explorer, 1.4 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge, Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At Low Speeds > Page 7281 MKX: Replace Three Wheels and Lubricate Remaining Wheel. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), Balance And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 091102D 2007-2008 Explorer, 1.6 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge, MKX: Replace Four Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) DEALER CODING CONDITION BASIC PART NO. CODE 1007 68 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels When Turning Wheels: All Technical Service Bulletins Wheels/Tires - Popping Noise From Wheels When Turning TSB 07-23-4 11/26/07 POPPING/SNAPPING NOISE - FRONT OR REAR 18 INCH WHEELS - TURNING AT SLOW SPEEDS BELOW 10 MPH (16KM/H) FORD: 2007 Edge 2007-2008 Explorer Sport Trac, Explorer MERCURY: 2007-2008 Mountaineer This article supersedes TSB 07-19-6 to update the vehicle lines. ISSUE Some 2007-2008 Explorer, Explorer Sport Trac and Mountaineer vehicles built prior to 8/17/2007 and 2007 Edge vehicles built prior to 8/24/2007 and equipped with 18" wheels may exhibit noise coming from the front or rear wheel(s) while turning the steering wheel at speeds lower than 10 MPH (16 Km/h). The noise may be coming from the chrome cladding that attaches to the rim. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE IF THE SOURCE OF NOISE IS NOT FROM THE WHEEL, FOLLOW NORMAL WORKSHOP MANUAL PROCEDURES. 1. Verify the noise is coming from the wheel(s). 2. Replace wheel(s) with updated service parts for 18" Chrome (Bright) Clad Cast Aluminum wheel and Satin Clad Cast Aluminum wheel(s). Refer to Workshop Manual (WSM), Section 204-04. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels When Turning > Page 7286 3. Lubricate the remaining wheels at the outboard wheel flange, between the cladding and the wheel inter[ace. Use Motorcraft Silicone Spray Lubricant and spray lubricant with an extension nozzle. (Figures 1 and 2) NOTE NEW WHEELS WILL NOT REQUIRE LUBRICATION. 4. Clean any excess lubricate off the wheel with a soft cloth. 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 072304A 2007-2008 Explorer, 0.9 Hr. Explorer Sport Trac, Mountaineer, 2007 Edge: Replace One Wheel and Lubricate Remaining Three Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1) 072304B 2007-2008 Explorer, 1.1 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge: Replace Two Wheels and Lubricate Remaining Two Wheels. Includes Test Drive, Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 072304C 2007-2008 Explorer, 1.4 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge: Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels When Turning > Page 7287 Replace Three Wheels and Lubricate Remaining Wheel. Includes Test Drive, Transfer TPMS, Balance And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) 072304D 2007-2008 Explorer, 1.6 Hrs. Explorer Sport Trac, Mountaineer, 2007 Edge: Replace Four Wheels. Includes Test Drive, Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1) DEALER CODING CONDITION BASIC PART NO. CODE 1007 68 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 07-12-2 > Jun > 07 > Wheels - 16 Inch Wheel Clear Coat Peeling/Cracking Wheels: All Technical Service Bulletins Wheels - 16 Inch Wheel Clear Coat Peeling/Cracking TSB 07-12-2 06/25/07 16 INCH BRIGHT MACHINED WHEEL-CORROSION AND ETCHING FORD: 2006-2007 Explorer 2007 Explorer Sport Trac ISSUE Some 2006-2007 Explorer and 2007 Explorer Sport Trac vehicles equipped with 16 inch wheels may exhibit the clear coat peeling off the wheel or cracks in the clear coat that look like spider webs. ACTION Replace affected wheel or wheels with new wheels that have added corrosion protection. SERVICE PROCEDURE Please review illustration shown below. To service, replace only affected wheel or wheels. Refer to Workshop Manual Section 204-04 for wheel removal and installation procedures. See example of affected wheel in Figure 1. Parts Block 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 071202A 2006-2007 Explorer, 2007 0.5 Hr. Explorer Sport Trac: Replace One Wheel, Includes Time To Transfer Tire Pressure Monitor Sensor (TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1, 1552A, 1007D3) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 07-12-2 > Jun > 07 > Wheels - 16 Inch Wheel Clear Coat Peeling/Cracking > Page 7292 071202B 2006-2007 Explorer, 2007 0.7 Hr. Explorer Sport Trac: Replace Two Wheels, Includes Time To Transfer Tire Pressure Monitor Sensor (TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1, 1552A, 1007D3) 071202C 2006-2007 Explorer, 2007 1.0 Hr. Explorer Sport Trac: Replace Three Wheels, Includes Time To Transfer Tire Pressure Monitor Sensor (TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1, 1552A, 1007D3) 071202D 2006-2007 Explorer, 2007 1.2 Hrs. Explorer Sport Trac: Replace All Wheels, Includes Time To Transfer Tire Pressure Monitor Sensor (TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1, 1552A, 1007D3) DEALER CODING CONDITION BASIC PART NO. CODE 1007 D4 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Wheel Bearing and Wheel Hub Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number or an equivalent part must be installed, if installation is necessary. Do not use a part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose can occur. Remove the bolts and position the caliper, pads and anchor plate assembly aside. ^ Discard the bolts. ^ Support the caliper and anchor plate assembly using mechanic's wire. ^ To install, tighten to 165 Nm (122 ft. lbs.) 3. Remove the brake disc. 4. CAUTION: Inspect and if necessary, clean area around wheel speed sensor before removing it from the wheel bearing and hub. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 7297 Remove the wheel speed sensor bolt and disconnect the wheel speed sensor from the wheel bearing and hub assembly. ^ To install, tighten to 18 Nm (13 ft. lbs.) 5. Remove the 3 bolts and the wheel bearing and hub assembly. ^ Discard the bolts. ^ To install, tighten to 122 Nm (90 ft. lbs.) 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 7298 Wheel Bearing: Service and Repair Rear Wheel Bearing and Wheel Hub Special Tool(s) Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Remove the wheel knuckle. 2. Remove the 3 brake disc shield bolts. ^ To install, tighten to 8 Nm (71 inch lbs.) 3. Using the special tool and a suitable press, remove the wheel hub. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 7299 4. Remove the snap ring. 5. Using a suitable press and adapters, remove the wheel bearing. 6. To install, reverse the removal procedure. 7. Install the wheel knuckle. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Testing and Inspection > Driveline System Wheel Hub: Testing and Inspection Driveline System Inspection and Verification Certain axle and driveline symptoms are also common to the engine, transmission, wheel bearings, tires and other parts of the vehicle. For this reason, be sure that the cause of the concern is in the axle before disassembling, adjusting or repairing the axle. Refer to Vehicle/Testing and Inspection. Certain driveshaft vibration symptoms are common to the front engine accessory drive (FEAD), the engine, transmission or tires. Be sure the cause of the concern is the driveshaft before repairing or installing a new driveshaft. Refer to Vehicle/Testing and Inspection. Noise Acceptability A gear-driven unit will produce a certain amount of noise. Some noise is acceptable and audible at certain speeds or under various driving conditions, such as a newly paved blacktop road. Slight noise is not detrimental to the operation of the axle and is considered normal. Universal Joint (U-Joint) Inspection Place the vehicle on a frame hoist and rotate the driveshaft by hand. Check for rough operation or seized U-joints. Install a new U-joint if it shows signs of seizure, excessive wear or incorrect seating. Analysis of Leakage Clean up the leaking area enough to identify the exact source. An axle leak can be caused by: ^ Axle lubricant level is too high ^ Worn or damaged axle shaft seals or differential seals ^ Differential housing is cracked ^ Flange yoke seal is worn or damaged ^ Pinion flange is scored or damaged ^ Axle cover is not sealed ^ Vent is plugged Repair the axle as necessary. Make sure the axle lubricant is at the correct level. Axle Vent NOTE: If a plugged vent cannot be cleared, install a new vent. NOTE: If the vent is removed from the housing for any reason, a new vent must be installed. A plugged vent will cause excessive seal lip wear due to internal pressure buildup. If a leak occurs, check the vent. Make sure the vent hose is not kinked. Remove the hose from the vent nipple and clear the hose of any foreign material. While the hose is removed, pass a length of mechanic's wire or a small diameter Allen wrench in and out of the vent to clean it. Connect the hose when done. Flange Yoke Seal Leaks at the axle drive pinion seal originate for these reasons: ^ The seal is not correctly installed ^ A poor quality seal journal surface Any damage to the seal bore (dings, dents, gouges or other imperfections) will distort the seal casing and allow leakage past the outer edge of the axle drive pinion seal. The axle drive pinion seal can be torn, cut or gouged if it is not installed carefully. The spring that holds the axle drive pinion seal against the pinion flange can be knocked out, which can allow leakage past the lip. The rubber lips can occasionally become hard (like plastic) with cracks at the oil lip contact point. The contact point on the pinion flange may blacken, indicating excessive heat. Marks, nicks, gouges or rough surface texture on the seal journal of the pinion flange will also cause leaks. A new pinion flange must be installed if any of these conditions exist. Metal chips or sand trapped at the sealing lip can also cause oil leaks. This can cause a wear groove on the pinion flange and heavy pinion seal wear. When a seal leak occurs, install a new seal and check the vent and the vent hose to make sure they are clean and free of foreign material. Analysis of Vibration WARNING: An all-wheel drive (AWD) vehicle will always have all wheels (on both axles) driving. If only one wheel/axle is raised off the floor and the axle is driven by the engine, the wheel/axle on the floor could drive the vehicle off the stand or jack. Be sure all wheels are off the floor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Testing and Inspection > Driveline System > Page 7304 Few vibration conditions are caused by the front or rear axle. For a vibration concern, follow the diagnosis procedure in Vehicle/Testing and Inspection unless there is a good reason to suspect the axle. Tires WARNING: Do not balance the wheels and tires while they are mounted on the vehicle. Possible tire disintegration or differential failure could result, causing personal injury or extensive component damage. Use an off-vehicle wheel and tire balancer only. Most vibration is caused by tires, driveline angle or driveline imbalance. Vibration is a concern with modern, high-mileage tires if they are not "true" both radially and laterally. They are more susceptible to vibration around the limits of radial and lateral runout of the tire and wheel assembly. They also require more accurate balancing. Wheel and tire runout checks, truing and balancing are normally done before axle inspection. Driveline Imbalance Driveline imbalance can be caused by excessive looseness in the driveshaft, damaged driveshaft tubing, looseness or high runout at the driveshaft attachments (axle and transfer case flanges). Excessive looseness in the driveshaft can be caused by CV joint or universal joint wear, as well as loose fitting slip-yoke splines. Inspect and install new driveshaft components as necessary. Driveline Angle Driveline Angle Driveline angularity is the angular relationship between the engine crankshaft, the driveshaft and the rear axle pinion. Some of the factors determining driveline angularity include ride height, rear spring and engine mounts. An incorrect driveline (pinion) angle can often be detected by examining the driving condition in which the vibration occurs. ^ A vibration during coastdown, from 72 to 56 km/h (45 to 35 mph), is often caused by an excessive U-joint angle at the axle (pinion nose downward). ^ A vibration during acceleration, from 56 to 72 km/h (35 to 45 mph), may indicate an excessive U-joint angle at the axle (pinion nose upward). When these conditions exist, check the driveline angles. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Testing and Inspection > Driveline System > Page 7305 Universal Joint (U-Joint) Wear Place the vehicle on a frame hoist and rotate the driveshaft by hand. Check for rough operation or seized U-joints. Install a new U-joint if it shows signs of seizure, excessive wear or incorrect seating. Wheel Hub Bolt Circle Runout NOTE: The brake discs must be removed to carry out all runout measurements. 1. Position the special tool on the wheel hub bolt, as close to the hub face as possible. Zero the indicator to allow the pointer to deflect either way. 2. Rotate the hub until the next bolt is contacted. Record the measurement and continue until each bolt is checked. The difference between the maximum and minimum contact readings will be the total wheel hub bolt circle runout. The runout must not exceed 0.38 mm (0.015 inch). Pilot Runout 1. Position the special tools on the pilot, as close to the hub as possible. Zero the indicator to allow the pointer to deflect either way. 2. Rotate the hub one full turn and note the maximum and minimum readings. The difference between the maximum and minimum readings will be the total pilot runout. Pilot runout must not exceed 0.15 mm (0.006 inch). Wheel Hub Runout 1. Position the special tool on the wheel hub, as close to the outer edge as possible. Zero the indicator to allow the pointer to deflect either way. 2. Rotate the hub one full turn and note the maximum and minimum readings. The difference between the maximum and minimum readings will be the total wheel hub runout. The runout must not exceed 0.127 mm (0.005 inch). Drive Pinion Stem and Pinion Flange Check the pinion flange runout when all other checks have failed to show the cause of the vibration. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Testing and Inspection > Driveline System > Page 7306 One cause of excessive pinion flange runout is incorrect installation of the axle drive pinion seal. Check to determine if the spring on the seal lip has been dislodged. Halfshafts NOTE: Constant velocity (CV) joints must not be installed unless disassembly and inspection reveals unusual wear. NOTE: While inspecting the boots, watch for indentations ("dimples") in the boot convolutions. Indentations must be removed. ^ Inspect the boots for evidence of cracks, tears or splits. ^ Inspect the underbody for any indication of grease splatter near the boots outboard and inboard locations. This is an indication of boot/clamp damage. Axle Noise NOTE: Before disassembling the axle to diagnose and correct gear noise, eliminate the tires, exhaust, trim items, roof racks and wheel bearings as possible causes. Follow the diagnostic procedures in Vehicle/Testing and Inspection. The noises described as follows usually have specific causes that can be diagnosed by observation as the unit is disassembled. The initial clues are the type of noise heard during the road test. Gear Howl and Whine Howling or whining of the ring gear and pinion is due to an incorrect gear pattern, gear damage or incorrect bearing preload. Bearing Whine Bearing whine is a high-pitched sound similar to a whistle. It is usually caused by worn/damaged pinion bearings, which are operating at driveshaft speed. Bearing noise occurs at all driving speeds. This distinguishes it from gear whine which usually comes and goes as speed changes. As noted, pinion bearings make a high-pitched, whistling noise, usually at all speeds. If however there is only one pinion bearing that is worn/damaged, the noise may vary in different driving phases. New pinion bearings must not be installed unless they are scored or damaged, or there is a specific pinion bearing noise. A worn/damaged bearing will normally be obvious at disassembly. Examine the large end of the rollers for wear. If the pinion bearings original blend radius has worn to a sharp edge, a new pinion bearing must be installed. A wheel bearing noise can be mistaken for a pinion bearing noise. On rear wheel drive (RWD) vehicles, check the wheel bearing for a spalled cup and spalled/damaged rollers. Install a new wheel bearing if any of these concerns are detected. On four wheel drive (4WD) vehicles, check the wheel bearing for rotating smoothness and end play. Chuckle Chuckle that occurs on the coast driving phase is usually caused by excessive clearance between the differential gear hub and the differential case bore. Damage to a gear tooth on the coast side can cause a noise identical to a chuckle. A very small tooth nick or ridge on the edge of a tooth can cause the noise. Clean the gear tooth nick or ridge with a small grinding wheel. If the damaged area is larger than 3.2 mm (1/8 inch), install a new gearset. To check the ring gear and pinion, remove as much lubricant as possible from the gears with clean solvent. Wipe the gears dry or blow them dry with compressed air. Look for scored or damaged teeth. Also look for cracks or other damage. If either gear is scored or damaged badly, a new ring gear and pinion must be installed. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Testing and Inspection > Driveline System > Page 7307 If metal has broken loose, the axle housing must be cleaned to remove particles that will cause damage. At this time, any other damaged parts in the axle housing must also be installed new. Knock Knock, which can occur in all driving phases, has several causes including damaged teeth or gearset. 1. NOTE: Measure the end play with a Dial Indicator with Bracketry and not by feel. Knock is also caused by excessive end play in the axle shafts. Up to 0.762 mm (0.030 inch) is allowed in semi-float axles. The frequency of the knock will be less because the axle shaft speed is slower than the driveshaft. Clunk Clunk is a metallic noise heard when the automatic transmission is engaged in REVERSE or DRIVE. The noise can also occur when throttle is applied or released. It is caused by backlash somewhere in the driveline or loose suspension components; it is felt or heard in the axle. Additionally, clunk may be heard upon initial drive-away. This occurs as engine torque shifts vehicle weight, forcing changes in driveline angles which prevent the driveshaft slip-yoke from sliding on the output shaft. To correct this condition, lubricate the slip-yoke splines. Bearing Rumble Bearing rumble sounds like marbles being tumbled. This condition is usually caused by a worn/damaged wheel bearing. The lower pitch is because the wheel bearing turns at only about 1/3 of the driveshaft speed. Wheel bearing noise also may be high-pitched, similar to gear noise, but will be evident in all 4 driving modes. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Testing and Inspection > Driveline System > Page 7308 Wheel Hub: Testing and Inspection Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear Inspection and Verification Special Tool(s) Material The technician should have a thorough knowledge of driveline system operation and accepted general driveline guidelines to detect any problems. A gear driven unit will produce a certain amount of noise. Some noise is acceptable and audible at certain speeds or under various driving conditions. Certain conditions, such as road conditions and weather, will amplify normal vehicle noise. Certain rear axle and driveline concern symptoms are also common to the engine, transmission, rear wheel bearings and tire. For this reason, be sure the cause of the concern is in the axle before repairing or installing any axle components. This is a guide to diagnose a driveline concern: ^ Verify and document the customer concern. ^ Carry out a preliminary investigation. ^ Road test the vehicle. ^ Find the cause of the problem. ^ Inspect the components. 1. Verify and document the customer concern. 1 When was it first noticed? 2 Did it appear suddenly or gradually? 3 Did anything unusual occur that would coincide with it or precede it? 4 Has the driveline system been repaired before or new components installed? ^ Check the vehicle service record. Note any repairs other than driveline, such as brakes or suspension. 5 Are there any special conditions that will affect the concern or will alter the concern? For example, ^ road speed. ^ type of road. ^ drive mode. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Testing and Inspection > Driveline System > Page 7309 ^ temperature. ^ vehicle loaded or unloaded. 6 Is the condition constant or intermittent? Can the concern be duplicated at any time? 7 Check for TSBs. 2. NOTE: If the inspection reveals an obvious concern, repair the vehicle. Do a preliminary investigation. Visually inspect for obvious signs of damage. 1 Inspect the driveshaft: ^ for build up of any foreign material. ^ for damage, such as a bent tube or missing weights. ^ U-joints, CV joints or flex couplers for wear or damage. 2 Inspect the axle: ^ for signs of leakage at the drain or fill plug, differential seal, vent or halfshaft seals. a plugged vent or vent tube will cause a leak. ^ for damage, such as cracks, bent halfshafts or dented rear cover. ^ for missing fasteners. 3 Inspect other suspect components/systems: ^ inspect the suspension for broken springs, damaged shock absorbers and worn suspension bushings. ^ inspect the rear brake components - lines, cables and calipers. ^ inspect the tires; are they in good condition and do they match? 3. NOTE: A road test is necessary for any customer concern of noise or vibration. Road test the vehicle. 1 During the road test, use these driving methods to diagnose the problem. Is the concern most noticeable: ^ from a stop? ^ on shifts from REVERSE to DRIVE? ^ on turns? sweeping type turn. - tight turn (to the stop). ^ in DRIVE? accelerating the vehicle, definite throttle depression, applying engine torque. ^ in CRUISE? - maintaining a constant speed with the throttle applied. ^ in COAST? decelerating with the throttle closed. 2 Record when the concern occurs. Write down the kph (mph) range at which the noise/vibration occurs. 4. Find the cause of the problem. 1 Compare the inspection and road test results with the chart. 2 Use this diagnostic routine chart to identify the probable cause and know what corrective actions should be taken to repair the component/vehicle and to prevent a reoccurrence. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Testing and Inspection > Driveline System > Page 7310 Diagnostic Routine Chart 5. NOTE: If the conclusion of the road test points to an axle assembly section (ring and pinion or differential case) concern, carry out a visual inspection of the rear axle. Inspect the axle components. 1 Remove the axle assembly. 2 Remove the differential housing cover. Drain the axle lubricant through a white cloth. Check the fluid for: ^ any foreign material. ^ metal particles. ^ burnt odor. 3 NOTE: When inspecting the axle, do not clean the components immediately. Cleaning may remove diagnostic evidence. Inspect the axle components. ^ Look for: loose fasteners. - notches or visible steps or grooves created by wear. - pitting or cracking along gear contact lines. - scuffing or deformations. - discolorations. - nicks or ridges on gear teeth. ^ Clean the axle components for inspection. Remove as much lubricant as possible with clean solvent. Wipe the components or blow them dry with compressed air. ^ Re-inspect for: Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Testing and Inspection > Driveline System > Page 7311 - loose fasteners. - notches or visible steps or grooves created by wear. - pitting or cracking along gear contact lines. - scuffing or deformations. - discolorations. - nicks or ridges on gear teeth. ^ Check backlash and carry out a ring and pinion pattern test. See: Transmission and Drivetrain/Differential Assembly/Testing and Inspection/Component Tests and General Diagnostics/Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear/Checking Tooth Contact Pattern and Condition of The Ring and Pinion Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Front Wheel Hub: Service and Repair Front Wheel Bearing and Wheel Hub Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number or an equivalent part must be installed, if installation is necessary. Do not use a part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose can occur. Remove the bolts and position the caliper, pads and anchor plate assembly aside. ^ Discard the bolts. ^ Support the caliper and anchor plate assembly using mechanic's wire. ^ To install, tighten to 165 Nm (122 ft. lbs.) 3. Remove the brake disc. 4. CAUTION: Inspect and if necessary, clean area around wheel speed sensor before removing it from the wheel bearing and hub. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Front > Page 7314 Remove the wheel speed sensor bolt and disconnect the wheel speed sensor from the wheel bearing and hub assembly. ^ To install, tighten to 18 Nm (13 ft. lbs.) 5. Remove the 3 bolts and the wheel bearing and hub assembly. ^ Discard the bolts. ^ To install, tighten to 122 Nm (90 ft. lbs.) 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Front > Page 7315 Wheel Hub: Service and Repair Rear Wheel Bearing and Wheel Hub Special Tool(s) Removal and Installation CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Remove the wheel knuckle. 2. Remove the 3 brake disc shield bolts. ^ To install, tighten to 8 Nm (71 inch lbs.) 3. Using the special tool and a suitable press, remove the wheel hub. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Front > Page 7316 4. Remove the snap ring. 5. Using a suitable press and adapters, remove the wheel bearing. 6. To install, reverse the removal procedure. 7. Install the wheel knuckle. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel Lug Nuts .......................................................................................................................................................... 135 Nm (100 ft. lbs.) in a star pattern Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front Wheel Studs Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose can occur. Remove the bolts and position the caliper, pads and anchor plate assembly aside. ^ Support the caliper and anchor plate assembly using mechanic's wire. ^ To install, tighten to 200 Nm (148 ft. lbs.) 3. Remove the brake disc. 4. Using the special tool, remove the wheel stud. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 7322 Installation 1. CAUTION: Do not use power tools to install the wheel stud. The serrations on the stud can be stripped. NOTE: Do not use the wheel nut that came with the vehicle. Install washers and a new wheel nut on the wheel stud and tighten the nut until the stud seats against the flange. ^ Discard the wheel nut and washers. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 7323 Wheel Fastener: Service and Repair Rear Wheel Studs Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 7324 Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. CAUTION: Orientation of the suspension fasteners is important. Make sure the fasteners are installed in the same direction as they were in when removed. 1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair. 2. CAUTION: Care must be used when servicing rear brake components without disconnecting the parking brake cable from the brake caliper lever. Carefully position the caliper aside using a suitable support or damage to the parking brake cable end fittings can occur. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose can occur. Remove the bolts and position the brake caliper aside. ^ Support the caliper using mechanic's wire. 3. Remove the brake disc. 4. Remove the parking brake shoe adjuster spring and adjuster. 5. CAUTION: The brake shield has an access hole knockout that must be removed to allow for the removal of the wheel stud. Using a suitable punch, remove the access hole cover from the brake shield. 6. NOTE: Make sure that the wheel stud is aligned with the recessed area of the wheel knuckle. Using the special tool, press the wheel stud until it makes contact with the edge of the wheel knuckle. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 7325 7. Route the wheel stud through the access hole and discard the wheel stud. Installation 1. Position the new wheel stud aligning the serrations in the wheel hub made by the original wheel stud. 2. CAUTION: Do not use power tools to install the wheel stud. The serrations on the stud can be stripped. NOTE: Do not use the wheel nut that came with the vehicle. Place flat washers over the outside end of the wheel stud and thread a standard wheel nut with the flat side against the washers. Tighten the wheel nut until the wheel stud seats against the back side of the wheel extension. ^ Discard the wheel nut and washers. 3. CAUTION: A plug must be installed in place of the knockout to prevent contamination to the parking brake shoe assemblies. Install a plug into the access hole on the brake shield. 4. Install the parking brake shoe adjuster and spring. 5. Install the brake disc. 6. Position the brake caliper and install the bolts. ^ Tighten to 32 Nm (24 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Description and Operation Accumulator HVAC: Description and Operation SUCTION ACCUMULATOR NOTE: Installation of a new suction accumulator 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. The suction accumulator is located at the RH rear of the engine compartment. The suction accumulator is used to prevent residual liquid refrigerant from reaching the A/C compressor after leaving the evaporator core. The suction accumulator allows the accumulated heavier liquid refrigerant and oil mixture to re-enter the compressor suction line at a controlled rate. A desiccant bag is mounted inside the canister to absorb any moisture which may be in the refrigerant system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair > Suction Accumulator Accumulator HVAC: Service and Repair Suction Accumulator SUCTION ACCUMULATOR Removal and Installation NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the suction accumulator. All vehicles 1. Recover the refrigerant. 2. Remove the PCM. 3. Remove the low-side service port stem bracket bolt. - To install, tighten to 11 Nm (8 lb-ft). 4. Disconnect the A/C cycling switch electrical connector. 5. Remove the suction accumulator bolt. - To install, tighten to 11 Nm (8 lb-ft). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair > Suction Accumulator > Page 7332 6. Remove the PCM bracket bolt. 7. Remove the PCM bracket nut and the PCM bracket. 8. Remove the suction accumulator stud. - To install, tighten to 11 Nm (8 lb-ft). 4.6L vehicles 9. Remove the suction accumulator-to-compressor line bracket nut at the condenser-to-evaporator line bracket. All vehicles 10. Remove the 2 suction accumulator fitting nuts and disconnect the fittings. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 11. Remove the suction accumulator bracket bolt and suction accumulator. 12. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 13. Evacuate, leak test and charge the refrigerant system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair > Suction Accumulator > Page 7333 Accumulator HVAC: Service and Repair Suction Accumulator to Compressor Line SUCTION ACCUMULATOR TO COMPRESSOR LINE Removal and Installation NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the suction accumulator. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the compressor suction fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (11 lb-ft). 4. Release the brake booster vacuum hose clamp and disconnect the hose. 5. Remove the suction accumulator-to-compressor line bracket bolt at the dash panel. - To install, tighten to 11 Nm (8 lb-ft). 6. Remove the suction accumulator outlet fitting nut. - To install, tighten to 8 Nm (71 lb-in). 7. Disconnect the auxiliary evaporator outlet line fitting (if equipped). - Discard the O-ring seals. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair > Suction Accumulator > Page 7334 8. Remove the suction accumulator-to-compressor line. - Discard the O-ring seal. 9. To install, reverse the removal procedure. - Install new O-ring seals and a new gasket seal. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 10. Evacuate, leak test and charge the refrigerant system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair > Suction Accumulator > Page 7335 Accumulator HVAC: Service and Repair Suction Accumulator to Evaporator Line SUCTION ACCUMULATOR TO EVAPORATOR LINE Removal and Installation NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the suction accumulator. All vehicles 1. Remove the suction accumulator. 2. Remove the powertrain control module (PCM) and PCM bracket. 3. Remove the A/C line bracket nut at the dash panel and remove the A/C line bracket. - To install, tighten to 6 Nm (53 lb-in). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair > Suction Accumulator > Page 7336 4. Remove the ground strap bolt at the dash panel. 5. Disconnect the evaporator outlet fitting. - Discard the O-ring seals. Vehicles with 4.0L engine 6. Disconnect he evaporative emissions return line fitting at the intake manifold. 7. Remove the fuel line bracket bolt at the rear of the RH valve cover. 8. Remove the wire harness bolt at the rear of the RH cylinder head. All vehicles 9. Remove the suction accumulator-to-evaporator line. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair > Suction Accumulator > Page 7337 10. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Locations View 151-30 (Steering Wheel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Locations > Page 7341 C2208 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Temperature Blend Door Actuator, Driver Air Door Actuator / Motor: Locations Temperature Blend Door Actuator, Driver View 151-27 (Front HVAC) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Temperature Blend Door Actuator, Driver > Page 7347 View 151-28 (Front HVAC) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Temperature Blend Door Actuator, Driver > Page 7348 View 151-15 (Left Rear, (1 0f 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Temperature Blend Door Actuator, Driver > Page 7349 View 151-15 (Left Rear, (1 0f 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Temperature Blend Door Actuator, Driver > Page 7350 View 151-28 (Front HVAC) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Blend Door Actuator, Rear C3004 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Blend Door Actuator, Rear > Page 7353 C2091 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Blend Door Actuator, Rear > Page 7354 C2092 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Blend Door Actuator, Rear > Page 7355 C3044 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Temperature Blend Door Actuator - LH Air Door Actuator / Motor: Service and Repair Temperature Blend Door Actuator - LH TEMPERATURE BLEND DOOR ACTUATOR - LH Removal and Installation 1. Remove the LH floor console finish panel. 2. Position the in-vehicle temperature sensor aspirator hose away from the LH temperature blend door actuator. 3. Remove the 3 LH temperature blend door actuator screws. 4. Disconnect the LH temperature blend door actuator electrical connector. 5. Remove the LH temperature blend door actuator. 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Temperature Blend Door Actuator - LH > Page 7358 Air Door Actuator / Motor: Service and Repair Temperature Blend Door Actuator - RH, EATC TEMPERATURE BLEND DOOR ACTUATOR - RH, EATC Removal and Installation 1. Remove the RH floor console finish panel. 2. Lower the glove compartment. 3. Disconnect the RH temperature blend door actuator electrical connector. 4. Remove the 3 RH temperature blend door actuator screws. 5. Remove the RH temperature blend door actuator. 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Temperature Blend Door Actuator - LH > Page 7359 Air Door Actuator / Motor: Service and Repair Vacuum Control Motor Air Inlet Door VACUUM CONTROL MOTOR - AIR INLET DOOR Removal and Installation 1. Lower the glove compartment. 2. Remove the screws and the heater core and evaporator core housing support brace. 3. Disconnect the air inlet door vacuum control motor vacuum connector. 4. Remove the 2 air inlet door vacuum control motor screws. 5. Rotate the air inlet door vacuum control motor until it clears the retaining arm and remove the vacuum control motor. 6. To install, reverse the removal procedure. Defroster Door VACUUM CONTROL MOTOR - DEFROSTER DOOR Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Temperature Blend Door Actuator - LH > Page 7360 Removal and Installation 1. Remove the audio unit. 2. Remove the lower steering column cover. 3. Remove the 3 center panel duct screws and position the center panel duct aside. 4. Remove the 2 plenum chamber screws. 5. Disconnect the defrost door vacuum control motor vacuum connector. 6. Remove the 2 defrost door vacuum control motor screws. 7. NOTE: The plenum chamber must be slightly repositioned to allow the defrost door vacuum control motor to be rotated far enough to clear the retaining arm. Rotate the defrost door vacuum control motor until it clears the retaining arm and remove the defrost door vacuum control motor. 8. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Temperature Blend Door Actuator - LH > Page 7361 Floor Door VACUUM CONTROL MOTOR - FLOOR DOOR Removal and Installation 1. Remove the center instrument panel finish panel. 2. Remove the shield screw. 3. Remove the shield. 4. Lower the glove compartment. 5. Disconnect the floor door vacuum control motor vacuum connector. 6. Detach the instrument panel harness pin-type retainer and position the harness aside. 7. Remove the 2 floor door vacuum control motor screws. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Temperature Blend Door Actuator - LH > Page 7362 8. Remove the RH floor console finish panel. 9. NOTE: The retaining arm must be slightly deflected away from the vacuum control motor arm to provide clearance. Partially actuate and rotate the floor door vacuum control motor until it clears the retaining arm and remove the vacuum control motor. 10. To install, reverse the removal procedure. Panel Door VACUUM CONTROL MOTOR - PANEL DOOR Removal and Installation 1. Remove the audio unit. 2. Lower the glove compartment. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Temperature Blend Door Actuator - LH > Page 7363 3. Remove the 3 center panel duct screws and position the center panel duct aside. 4. Remove the 2 plenum chamber screws. 5. Disconnect the panel door vacuum control motor vacuum connector. 6. Remove the 2 panel door vacuum control motor screws. 7. NOTE: The plenum chamber must be slightly repositioned to allow the panel door vacuum control motor to be rotated far enough to clear the retaining arm. Rotate the panel door vacuum control motor until it clears the retaining arm and remove the panel door vacuum control motor. 8. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Temperature Blend Door Actuator - LH > Page 7364 Air Door Actuator / Motor: Service and Repair Auxiliary Mode Door Actuator AUXILIARY MODE DOOR ACTUATOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the LH quarter trim panel. 3. Remove the 2 auxiliary line floorpan bracket nuts. - To install, tighten to 8 Nm (71 lb-in). 4. Remove the 2 auxiliary heater core and evaporator core housing bolts. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Temperature Blend Door Actuator - LH > Page 7365 - To install, tighten to 6 Nm (53 lb-in). 5. Remove the auxiliary heater core and evaporator core housing nut. - To install, tighten to 6 Nm (53 lb-in). 6. Disconnect the auxiliary harness electrical connector. 7. Disconnect the auxiliary mode door actuator electrical connector. 8. Remove the 3 auxiliary mode door actuator screws. 9. Remove the auxiliary mode door actuator. 10. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Temperature Blend Door Actuator - LH > Page 7366 Air Door Actuator / Motor: Service and Repair Auxiliary Temperature Blend Door Actuator AUXILIARY TEMPERATURE BLEND DOOR ACTUATOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the LH quarter trim panel. 3. Remove the 2 auxiliary line floorpan bracket nuts. - To install, tighten to 8 Nm (71 lb-in). 4. Remove the 2 auxiliary heater core and evaporator core housing bolts. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Temperature Blend Door Actuator - LH > Page 7367 - To install, tighten to 6 Nm (53 lb-in). 5. Remove auxiliary heater core and evaporator core housing nut. - To install, tighten to 6 Nm (53 lb-in). 6. Disconnect the auxiliary harness electrical connector. 7. Disconnect the auxiliary temperature blend door actuator electrical connector. 8. Remove the 3 auxiliary temperature blend door actuator screws. 9. Remove the auxiliary temperature blend door actuator. 10. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair Air Duct: Service and Repair AIR INLET DUCT Removal and Installation 1. Remove the heater core and evaporator core housing. 2. Remove the air inlet duct. 1 Remove the support bracket screw. 2 Disconnect the air inlet door vacuum control motor vacuum connector. 3 Remove the 3 air inlet duct screws. 4 Remove the air inlet duct. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations View 151-2 (Engine Compartment - 4.0L, (2 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7374 C132 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7375 Ambient Temperature Sensor / Switch HVAC: Service and Repair AMBIENT AIR TEMPERATURE SENSOR Removal and Installation Mountaineer 1. Remove the radiator grille. 2. Remove the pin-type retainers and position the air deflector forward. 3. Remove the 2 air deflector pin-type retainers and detach the air deflector from the 2 locator pins on the radiator support. All vehicles 4. Detach the ambient air temperature sensor electrical connector. 5. Remove the ambient air temperature sensor. 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Locations View 151-15 (Left Rear, (1 0f 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Locations > Page 7380 C3021 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Blower Motor Relay 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Blower Motor Relay 1 > Page 7385 View 151-27 (Front HVAC) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 7386 C2017 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay 1 > Page 7389 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Auxiliary Blower Motor Resistor Assembly View 151-15 (Left Rear, (1 0f 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Auxiliary Blower Motor Resistor Assembly > Page 7394 View 151-27 (Front HVAC) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Front Blower Motor Resistor Assembly C293 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Front Blower Motor Resistor Assembly > Page 7397 C3022 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor Blower Motor Resistor: Service and Repair Blower Motor Resistor BLOWER MOTOR RESISTOR Removal and Installation 1. Remove the 2 four wheel drive (4WD) control module screws. 2. Disconnect the blower motor resistor electrical connector. 3. Remove the 2 blower motor resistor screws. 4. Remove the blower motor resistor. 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor > Page 7400 Blower Motor Resistor: Service and Repair Auxiliary Blower Motor Resistor AUXILIARY BLOWER MOTOR RESISTOR Removal and Installation 1. Remove the switch bezel. 2. Disconnect the power lock switch electrical connector. 3. Remove the access panel. 4. Disconnect the auxiliary blower motor resistor electrical connector. 5. Remove the 2 auxiliary blower motor resistor screws. 6. Remove the auxiliary blower motor resistor. 7. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations View 151-28 (Front HVAC) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations > Page 7404 C271 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations > Page 7405 Blower Motor Switch: Service and Repair BLOWER MOTOR SPEED CONTROL Removal and Installation 1. Remove the blower motor speed control screw. 2. Remove the blower motor speed control. 3. Disconnect the blower motor speed control electrical connector. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair The air distribution system of this vehicle cannot be equipped with a cabin air filter. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 7412 C233 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 7413 Cabin Temperature Sensor / Switch: Service and Repair IN-VEHICLE TEMPERATURE SENSOR Removal and Installation 1. Remove the instrument cluster finish panel. 2. Remove the in-vehicle temperature sensor. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications Item....................................................................................................................................................... ..............................................................Specification Magnetic Clutch Air gap clearance.................................................................................................................................. .................................. 0.35-0.65 mm (0.014-0.026 in) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7418 Compressor Clutch: Adjustments AIR CONDITIONING (A/C) CLUTCH AIR GAP ADJUSTMENT 1. Check the A/C clutch air gap at 3 equally spaced places between the clutch plate and the A/C clutch pulley. 2. Remove the clutch plate. Add or remove spacers between the clutch plate hub and the compressor shaft until the clearance is within specification. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7419 Compressor Clutch: Service and Repair CLUTCH AND CLUTCH FIELD COIL Special Tool(s) Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7420 Removal All vehicles 1. Remove the A/C compressor. 2. Remove the A/C clutch disc and hub bolt. 1 Hold the A/C clutch disc and hub with the special tool. 2 Remove the A/C clutch disc and hub bolt. 3. Remove the A/C clutch disc and hub. 4. Remove the A/C compressor pulley snap ring. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7421 5. Remove the A/C compressor pulley. 1 Install the special tool. 2 Remove the A/C compressor pulley. FS18 compressors only 6. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. Remove the A/C clutch field coil. 1 Install the special tool. 2 Install the special tool. 3 Remove the A/C clutch field coil. FS20 compressors only 7. Remove the A/C clutch field coil snap ring. 8. Remove the A/C clutch field coil. Installation NOTE: If installing a new A/C compressor, the A/C clutch components should be reused unless obvious signs of damage are found. If excessive grooving is found, a new A/C clutch disc and hub and A/C compressor pulley must be installed together. Otherwise, each component can be installed individually where needed. All vehicles 1. Visually inspect the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil for damage. - Inspect for physical damage, including cracked or melted components or discoloration due to excessive heat. - Inspect for excessive wear, including grooving in the A/C clutch disc and hub or A/C compressor pulley that is more than fingernail depth. - Inspect for roughness in the A/C compressor pulley bearing. 2. Clean the A/C clutch field coil and pulley mounting surfaces. FS18 compressors only 3. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. 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 correctly positioned. 2 Place the special tool on the A/C clutch field coil. 3 Place the special tool 412-065 on the special tool 412-078. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7422 4 Use the special tool to install the A/C clutch field coil. FS20 compressors only 4. Install the A/C clutch field coil. 5. Install the A/C clutch field coil snap ring. All vehicles 6. NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head. It must be correctly aligned during installation. Install the A/C clutch pulley. 7. Install the A/C clutch pulley snap ring with the bevel side out. 8. Place one nominal thickness A/C clutch disc and hub spacer inside the clutch hub spline opening. 9. Install the A/C clutch disc and hub assembly. 10. Install the A/C clutch disc and hub bolt. 1 Hold the A/C clutch disc and hub with the special tool. 2 Install the A/C clutch disc and hub bolt. Tighten to 13 Nm (10 lb-ft). 11. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers. 12. Install the A/C compressor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Locations View 151-2 (Engine Compartment - 4.0L, (2 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Locations > Page 7426 C1110 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Locations > Page 7427 Compressor Clutch Coil: Service and Repair CLUTCH AND CLUTCH FIELD COIL Special Tool(s) Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Locations > Page 7428 Removal All vehicles 1. Remove the A/C compressor. 2. Remove the A/C clutch disc and hub bolt. 1 Hold the A/C clutch disc and hub with the special tool. 2 Remove the A/C clutch disc and hub bolt. 3. Remove the A/C clutch disc and hub. 4. Remove the A/C compressor pulley snap ring. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Locations > Page 7429 FS18 compressors only 5. Remove the A/C compressor pulley. 1 Install the special tool. 2 Remove the A/C compressor pulley. FS 20 compressors only 6. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. Remove the A/C clutch field coil. 1 Install the special tool. 2 Install the special tool. 3 Remove the A/C clutch field coil. 7. Remove the A/C clutch field coil snap ring. 8. Remove the A/C clutch field coil. Installation NOTE: If installing a new A/C compressor, the A/C clutch components should be reused unless obvious signs of damage are found. If excessive grooving is found, a new A/C clutch disc and hub and A/C compressor pulley must be installed together. Otherwise, each component can be installed individually where needed. All vehicles 1. Visually inspect the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil for damage. - Inspect for physical damage, including cracked or melted components or discoloration due to excessive heat. - Inspect for excessive wear, including grooving in the A/C clutch disc and hub or A/C compressor pulley that is more than fingernail depth. - Inspect for roughness in the A/C compressor pulley bearing. 2. Clean the A/C clutch field coil and pulley mounting surfaces. FS18 compressors only 3. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. 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 correctly positioned. 2 Place the special tool on the A/C clutch field coil. 3 Place the special tool 412-065 on the special tool 412-078. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Locations > Page 7430 4 Use the special tool to install the A/C clutch field coil. FS20 compressors only 4. Install the A/C clutch field coil. 5. Install the A/C clutch field coil snap ring. All vehicles 6. NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head. It must be correctly aligned during installation. Install the A/C clutch pulley. 7. Install the A/C clutch pulley snap ring with the bevel side out. 8. Place one nominal thickness A/C clutch disc and hub spacer inside the clutch hub spline opening. 9. Install the A/C clutch disc and hub assembly. 10. Install the A/C clutch disc and hub bolt. 1 Hold the A/C clutch disc and hub with the special tool. 2 Install the A/C clutch disc and hub bolt. - Tighten to 13 Nm (10 lb-ft). 11. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers. 12. Install the A/C compressor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 7434 Compressor Clutch Relay: Description and Operation AIR CONDITIONING (A/C) CLUTCH RELAY (A/CCR) NOTE: The PCM PIDs WAC and wide open throttle air conditioning cutoff fault (WACF) are used to monitor the A/CCR output. The A/CCR is wired normally open. There is no direct electrical connection between the A/C switch or electronic automatic temperature control (EATC) module and the A/C clutch. The PCM receives a signal indicating that A/C is requested. For some applications, this message is sent through the communications network. When A/C is requested, the PCM checks other A/C related inputs that are available, such as A/C pressure switch and A/C cycling switch. If these inputs indicate A/C operation is OK, and the engine conditions are OK (coolant temperature, engine RPM, throttle position), the PCM grounds the A/CCR output, closing the relay contacts and sending voltage to the A/CCR. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 7435 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation Condenser HVAC: Description and Operation CONDENSER CORE NOTE: Installation of a new suction accumulator 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. The condenser 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Page 7439 Condenser HVAC: Service and Repair CONDENSER CORE Removal and Installation NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the suction accumulator. 1. Recover the refrigerant. 2. Remove the air cleaner. 3. Remove the 2 coolant expansion tank bolts and position the coolant expansion tank aside. - To install, tighten to 7 Nm (62 lb-in) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Page 7440 4. Disconnect the A/C pressure transducer electrical connector. 5. Remove the condenser inlet fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). 6. Remove the condenser outlet fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). 7. Detach the 2 compressor-to-condenser discharge line clips. 8. Remove the 2 cooling module bolts and position the cooling module rearward. - To install, tighten to 12 Nm (9 lb-ft). 9. Remove the upper radiator air deflector. 10. Remove the 2 condenser core bolts. - To install, tighten to 12 Nm (9 lb-ft). 11. Remove the condenser core. 12. Remove the 2 condenser air deflectors. 13. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 14. Evacuate, leak test and charge the refrigerant system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Function Selector Switch Assembly, Rear View 151-26 (Roof) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Function Selector Switch Assembly, Rear > Page 7445 View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions Control Assembly: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7448 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7449 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7450 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7451 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7452 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7453 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7454 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7455 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7456 Control Assembly: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7457 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7458 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7459 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7460 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7461 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7462 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7463 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7464 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7465 Control Assembly: Connector Views C294A C294B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7466 C294C C951A Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 7467 C951B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Control Components Control Assembly: Description and Operation Control Components CONTROL COMPONENTS MANUAL CLIMATE CONTROL The manual climate control components are used to select: - air inlet source (outside or recirculated). - blower motor speed. - discharge air temperature (temperature blend). - discharge air location (defrost, panel, floor). - A/C compressor operation. Control System Inputs The climate control assembly has 3 system control inputs. Climate Control Assembly The climate control assembly integrates the temperature control switch, A/C request button and rear defog switch into a single unit. The temperature control switch setting determines air temperature. Temperature selection is accomplished with a potentiometer (temperature control switch) connected to the temperature blend door actuator. Movement of the temperature control switch from COOL (blue) to WARM (red) causes a corresponding movement of the temperature blend door and determines the air discharge temperature that the air distribution system will maintain. The temperature control switch is an integral part of the manual climate control assembly and a new one cannot be separately installed. The A/C request switch determines A/C compressor operation, except when the function selector switch is in the OFF, MAX, DEFROST or FLOOR/DEFROST positions. The A/C request switch is an integral part of the manual climate control assembly and a new one cannot be separately installed. The rear defog button signals activation of the heated backlight and heated mirrors. The rear defog button is an integral part of the manual climate control assembly and a new one cannot be separately installed. Function Selector Switch The function selector switch combines a vacuum selector valve that determines air distribution and an electrical switch to supply battery voltage to the A/C compressor circuit and the blower motor circuit. When the function selector switch is in the MAX A/C, DEFROST or FLOOR/DEFROST positions, the A/C compressor will be operational regardless of the A/C request switch status. Blower Motor Switch The blower motor switch controls blower motor speed by adding or bypassing resistors in the blower motor switch resistor in all function selector switch positions except OFF. Control System Outputs The climate control system has 5 system outputs. Blower Motor Resistor The blower motor resistor has 3 resistor elements mounted on the resistor board to provide 4 blower motor speeds. Depending on the blower motor switch position, series resistance is added or bypassed in the blower motor circuit to decrease or increase blower motor speed. The blower motor resistor has an overheating device (thermal limiter) that opens the resistor coil when the temperature reaches approximately 184°C (363°F), interrupting the blower motor operation in all speeds except HIGH. The thermal limiter cannot be reset and is not serviceable. Temperature Blend Door Actuator The temperature blend door actuator moves the temperature blend door on command from the temperature control switch using a reversible electric motor. The temperature blend door actuator contains an internal controller that will recognize the temperature control switch signal and drive the temperature blend door to the desired position. The temperature blend door actuator is located on the LH side of the heater core and evaporator core housing. Vacuum Control Motors The 4 vacuum control motors move the airflow mode doors to direct system airflow to the vehicle interior as determined by the function selector switch. Vacuum control motors are used to control the: air inlet door. - defrost mode door. - panel mode door. - floor mode door. Heater Control Valve Vacuum Switch Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Control Components > Page 7470 The heater control valve vacuum switch applies vacuum to the heater control valve when the temperature blend door is in the full COOL position. The temperature blend door actuates the heater control valve vacuum switch with an arm attached to the RH side of the temperature blend door pivot shaft. The heater control valve vacuum switch is mounted on the RH side of the heater core and evaporator core housing just below the defrost door vacuum control motor. DUAL-ZONE ELECTRONIC AUTOMATIC TEMPERATURE CONTROL The dual-zone electronic automatic temperature control (EATC) module analyzes input from the following major sources: - Temperature, airflow direction and blower selection (made by the vehicle occupants) - In-vehicle temperature - Ambient temperature - Sunload - Vehicle speed - Engine coolant temperature Using these inputs, the dual-zone EATC module determines the correct conditions for the following outputs: - A/C compressor operation - Blower speed - LH side temperature blend door position - RH side temperature blend door position - Air inlet mode door position - Defrost mode door position - Panel mode door position - Floor mode door position Control System Inputs The dual-zone EATC system has 5 control system inputs. Climate Control Assembly (Dual-Zone EATC Module) NOTE: If installing a new dual-zone EATC module, the new module must be configured for the vehicle. Refer to Information Bus (Module Communications Network). The dual-zone EATC module has a vacuum fluorescent display for displaying set temperature, airflow direction, blower speed and diagnostic trouble codes (DTCs). The dual-zone EATC module utilizes an on-board diagnostic (OBD) feature to supply the technician with DTCs. These DTCs help direct the technician to the inoperative component. Steering Wheel Audio/Climate Control Switch The steering wheel audio/climate control switch is located on the right side of the steering wheel. The steering wheel audio/climate control switch allows the driver to adjust the passenger compartment temperature setting and manually override the blower motor speed setting. Ambient Air Temperature Sensor The ambient air temperature sensor contains a thermistor which measures the temperature of outside air as a resistance and sends that reading to the dual-zone EATC module. In-Vehicle Temperature Sensor The in-vehicle temperature sensor contains a thermistor which measures the in-vehicle air temperature and sends that reading to the EATC module. A hose and elbow is connected between the heater core and evaporator core housing and the in-vehicle temperature sensor. The automatic temperature control sensor hose and elbow takes air from the heater core and evaporator core housing air stream to create a suction in the in-vehicle temperature sensor. The suction draws in-vehicle air into the in-vehicle temperature sensor and across the thermistor. Solar Radiation Sensor (Sunload Sensor) The solar radiation sensor supplies information to the dual-zone EATC module indicating LH side and RH side sunload. Control System Outputs The dual-zone EATC system has 4 control system outputs. Automatic Temperature Control (ATC) Solenoid and Manifold The ATC solenoid and manifold uses 5 internal solenoid-type valves to distribute vacuum to the vacuum control motors and heater control valve based on the dual-zone EATC module settings. Manifold vacuum is always available at the ATC solenoid and manifold from the vacuum reservoir when the engine is running. The 4 vacuum control motors and the heater control valve vacuum lines are each connected to a separate internal solenoid. The dual-zone EATC module will apply voltage to the desired solenoids to open the solenoid to the manifold vacuum supply and complete the vacuum circuit to the desired component. Blower Motor Speed Control Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Control Components > Page 7471 The blower speed control converts low power signals from the dual-zone EATC module to a high current, variable ground feed for the blower motor. A delay function is used to provide a gradual increase or decrease in blower motor speed under all conditions. Temperature Blend Door Actuators The dual-zone EATC system uses 2 temperature blend door actuators to control 2 separate temperature blend doors. The temperature blend doors independently vary the LH side and RH side temperature settings, as desired. The temperature blend door actuators each contain a reversible electric motor and a potentiometer. The dual-zone EATC module applies a 5-volt signal to one end of the potentiometer and ground to the other. The potentiometer wiper is connected to the actuator output shaft and moves with the output shaft. The voltage available at the wiper indicates the position of the temperature blend door. The actuator wiper voltage is sent to the dual-zone EATC module which drives the actuator motor in whichever direction is necessary to make the actuator wiper voltage agree with the expected dual-zone EATC module wiper voltage value. Vacuum Control Motors The 4 vacuum control motors move the airflow mode doors to direct system airflow to the vehicle interior as determined by the function selector switch. Vacuum control motors are used to control the air inlet door. - defrost mode door. - panel mode door. - floor mode door. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Control Components > Page 7472 Control Assembly: Description and Operation Heating and Ventilation HEATING AND VENTILATION The heating and ventilation system has the following features: - Controls the temperature and, during A/C operation, reduces the relative humidity of the air inside the vehicle. - Delivers heated or cooled air to maintain the vehicle interior temperature and comfort level. - Cooling or heating can be adjusted to maintain the desired temperature. - On vehicles with dual-zone electronic automatic temperature control (EATC), the temperature can be adjusted individually by the driver and passenger. Heater Core 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. Blower Motor The blower motor pulls air from the air inlet and forces it into the heater core and evaporator core housing and the plenum chamber where it is mixed and distributed. Heater Control Valve The heater control valve is actuated by the heater control valve vacuum switch (manual climate control) or the heater control valve vacuum control circuit (EATC). When the heater control valve is closed (full vacuum), coolant flow through the heater core is shut OFF and A/C cooling efficiency is increased. Heater Core and Evaporator Core Housing The heater core and evaporator core housing directs airflow from the blower motor through the evaporator core and heater core. All airflow from the blower motor passes through the evaporator core. The airflow is then directed through or around the heater core by the temperature blend door(s). Vehicles equipped with dual-zone EATC use a partitioned heater core and evaporator core housing with 2 electric actuator-positioned temperature blend doors. This allows for separate temperatures to be selected for the driver and passenger sides of the passenger compartment. Manual systems use a single electric actuator-positioned temperature blend door to direct airflow through or around the heater core. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Climate Control Assembly Control Assembly: Service and Repair Climate Control Assembly CLIMATE CONTROL ASSEMBLY Removal and Installation NOTE: If installing a new dual-zone electronic automatic temperature control (EATC) module, the new module must be configured for the vehicle. All vehicles 1. Remove the center instrument panel finish panel. 2. Remove the 4 climate control assembly screws. 3. Remove the climate control assembly. Vehicles with manual climate control 4. Remove the 3 climate control knobs. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Climate Control Assembly > Page 7475 5. Depress the tabs and remove the blower motor switch. 6. Depress the tabs and remove the function selector switch. All vehicles 7. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Climate Control Assembly > Page 7476 Control Assembly: Service and Repair Auxiliary Climate Control Assembly AUXILIARY CLIMATE CONTROL ASSEMBLY Removal and Installation 1. Remove the overhead console. 2. Remove the 2 screws. 3. Remove the bezel. 4. Remove the auxiliary climate control assembly. 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > Page 7480 Control Module HVAC: Diagrams C228A C228B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair Coupler HVAC: Service and Repair SPRING LOCK COUPLING Special Tool(s) Special Tool(s) Disconnect 1. Remove the spring lock coupling clip, if equipped. 2. 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. Push the tool into the cage opening to release the female fitting from the spring lock coupling spring and pull the fitting apart. Remove the O-ring seals using a non-metallic tool. 3. 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. Remove the spring lock coupling spring with a small hooked wire. Cleaning Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Page 7484 1. Fabricate a cleaning tool from a 1/8-in diameter brazing rod. 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 oil. 5. Roll the pad on the tool and install it in a variable speed drill motor. 6. CAUTION: Maintain low speed drill rotation when inserting or removing the cleaning tool to prevent axial scratches which may cause future leaks. 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. 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. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Page 7485 9. Clean the O-ring seal grooves with a 300 mm (12 in) 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 1. Install the spring lock coupling spring. 2. Lubricate the inside of the coupling with PAG oil. 3. CAUTION: Use only the new O-ring seals. The use of any O-ring seals other than those specified in the Ford Master Parts Catalog may result in intermittent leakage during vehicle operation. Install the O-ring seals. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Page 7486 4. Connect the spring lock coupling fittings with a twisting motion until the spring lock coupling spring snaps over the flared end of the female fitting. 5. Install the spring lock coupling clip. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation Evaporator Core: Description and Operation Evaporator Core NOTE: - If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it is removed from the vehicle. - Installation of a new suction accumulator 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. The evaporator core is an aluminum plate/fin type and is located in the heater core and evaporator core housing. A mixture of refrigerant and oil enters the bottom of the evaporator core through the evaporator core inlet tube and continues out of the evaporator core through the evaporator core outlet tube. Air from the blower motor is cooled and dehumidified as it flows through the evaporator core fins. Evaporator Core Orifice NOTE: A new evaporator core orifice should be installed whenever a new A/C compressor is installed. The evaporator core orifice is located in the condenser-to-evaporator line, and can be removed through an access fitting. The evaporator core orifice provides a restriction to the flow of refrigerant from the high-pressure side of the refrigerant system and separates the low-pressure and high-pressure sides of the refrigerant system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Page 7490 Evaporator Core: Service and Repair EVAPORATOR CORE Removal and Installation NOTE: If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it is removed from the vehicle. 1. Remove the heater core. 2. Remove the 5 outer evaporator core cover screws. 3. Remove the 6 inner evaporator core cover screws. 4. Separate the evaporator core cover from the heater core and evaporator core housing. - Discard the rope seal. 5. Remove the evaporator core. 6. To install, reverse the removal procedure. - Apply a bead of RTV sealant around the entire evaporator core housing groove joint in place of the rope seal. - Tighten the evaporator core cover screws in a diagonal pattern to distribute the RTV sealant evenly. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 09-22-15 > Nov > 09 > A/T Controls - MIL ON/Various A/T Solenoid DTC's Evaporator Drain Tube: Customer Interest A/T Controls - MIL ON/Various A/T Solenoid DTC's TSB 09-22-15 11/16/09 5R555 TRANSMISSION - CHECK ENGINE LIGHT ON - VARIOUS DTC'S - WATER INTRUSION FROM A/C DRAIN INTO TRANSMISSION SOLENOID BODY CONNECTOR - BUILT ON OR BEFORE 8/12/2009 FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Sport Trac vehicles built on or before 8/12/2009 and equipped with 5R55S transmission may exhibit a check engine light with diagnostic trouble code DTC P0713 and/or various transmission solenoid body connector related DTCs. This may be due to water traveling down from the A/C drain into the solenoid body connector on the left side of the transmission. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Verify any transmission related symptoms or transmission related DTC's that are present. 2. Check the transmission solenoid connector for signs of water intrusion, corrosion, that may be coming from the A/C drain. (Figure 1) 3. If present, clean the connector thoroughly and apply Motorcraft(R) Electrical Grease as needed. 4. Cut and install patch kit over the connector. (Figure 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 09-22-15 > Nov > 09 > A/T Controls - MIL ON/Various A/T Solenoid DTC's > Page 7499 Parts Block 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 092215A 2006-2010 Explorer, 0.4 Hr. Mountaineer 2007-2010 Explorer Sport Trac 4.0L: Check DTCs, Inspect, Clean, And Grease Connector, Install Patch (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7G391 X2 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 09-22-15 > Nov > 09 > A/T Controls - MIL ON/Various A/T Solenoid DTC's Evaporator Drain Tube: All Technical Service Bulletins A/T Controls - MIL ON/Various A/T Solenoid DTC's TSB 09-22-15 11/16/09 5R555 TRANSMISSION - CHECK ENGINE LIGHT ON - VARIOUS DTC'S - WATER INTRUSION FROM A/C DRAIN INTO TRANSMISSION SOLENOID BODY CONNECTOR - BUILT ON OR BEFORE 8/12/2009 FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Sport Trac vehicles built on or before 8/12/2009 and equipped with 5R55S transmission may exhibit a check engine light with diagnostic trouble code DTC P0713 and/or various transmission solenoid body connector related DTCs. This may be due to water traveling down from the A/C drain into the solenoid body connector on the left side of the transmission. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Verify any transmission related symptoms or transmission related DTC's that are present. 2. Check the transmission solenoid connector for signs of water intrusion, corrosion, that may be coming from the A/C drain. (Figure 1) 3. If present, clean the connector thoroughly and apply Motorcraft(R) Electrical Grease as needed. 4. Cut and install patch kit over the connector. (Figure 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 09-22-15 > Nov > 09 > A/T Controls - MIL ON/Various A/T Solenoid DTC's > Page 7505 Parts Block 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 092215A 2006-2010 Explorer, 0.4 Hr. Mountaineer 2007-2010 Explorer Sport Trac 4.0L: Check DTCs, Inspect, Clean, And Grease Connector, Install Patch (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7G391 X2 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation Evaporator Temperature Sensor / Switch: Description and Operation AIR CONDITIONING EVAPORATOR TEMPERATURE (ACET) SENSOR A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance The ACET sensor measures the evaporator air discharge temperature. The ACET sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The PCM sources a low current 5 volts on the ACET circuit. With SIG RTN also connected to the ACET sensor, the varying resistance changes the voltage drop across the sensor terminals. As A/C evaporator air temperature changes, the varying resistance of the ACET sensor changes the voltage the PCM detects. The ACET sensor is used to more accurately control A/C clutch cycling, improve defrost/demist performance, and reduce A/C clutch cycling. NOTE: These values can vary 15% due to sensor and VREF variations. Voltage values were calculated for VREF equals 5.0 volts. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair Expansion Block/Orifice Tube: Service and Repair EVAPORATOR CORE ORIFICE Special Tool(s) Special Tool(s) Removal NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the suction accumulator. 1. Recover the refrigerant. 2. NOTE: The evaporator core orifice access fitting is located in the condenser-to-evaporator line below the powertrain control module. Disconnect the evaporator core orifice access fitting. Discard the O-ring seal. 3. Inspect the evaporator core orifice for damage before attempting to remove it from the line. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair > Page 7512 4. If the evaporator core orifice is intact, engage the special tool. Hold the T-handle stationary while rotating the tool body to remove the evaporator core orifice. 5. If the evaporator core orifice is broken, screw the end of the special tool into the broken orifice. Hold the T-handle stationary while rotating the tool body to remove the evaporator core orifice. Installation 1. Lubricate the evaporator core orifice O-rings with clean PAG oil and install the evaporator core orifice using the special tool. 2. Install a new O-ring seal and connect the evaporator core orifice access fitting. - To install, tighten to 24 Nm (18 lb-ft). 3. Lubricate the refrigerant system with the correct amount of clean PAG oil. 4. Evacuate, leak test and charge the refrigerant system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair Expansion Valve: Service and Repair THERMOSTATIC EXPANSION VALVE Removal and Installation NOTE: - An in-line filter is installed in the auxiliary evaporator inlet line at the floorpan bracket connection. A restriction in this filter may cause misdiagnosis of a failed thermostatic expansion valve. This filter must be inspected before a new thermostatic expansion valve is installed. - Installation of a new suction accumulator is not required when repairing the air conditioning system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the suction accumulator. 1. Recover the refrigerant. 2. Remove the D-pillar trim panel. 3. Detach the rear portion of the LH quarter trim panel and position away from the thermostatic expansion valve. 4. Remove the 4 clips and the thermostatic expansion valve cover. 5. Remove the insulating tape. - Retain the tape for reuse. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > Page 7516 6. Remove the temperature sensing bulb clip and detach the temperature sensing bulb from the evaporator outlet line. 7. Disconnect the 2 thermostatic expansion valve fittings and remove the thermostatic expansion valve. - Discard the O-ring seals. - To install, tighten to 23 Nm (17 lb-ft). 8. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 9. Evacuate, leak test and charge the refrigerant system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Component Information > Service and Repair Heater Control Valve: Service and Repair HEATER CONTROL VALVE Removal and Installation Vehicles with 4.0L and oil cooler, without auxiliary climate control 1. With the vehicle in NEUTRAL, position it on a hoist. All vehicles 2. Drain the engine coolant. 3. Disconnect the 2 inlet and outlet heater hose clamps. 4. Disconnect the heater control valve vacuum hose. Vehicles with 4.0L and oil cooler, without auxiliary climate control 5. Remove the heater control valve bolt. All vehicles 6. Remove the heater control valve. 7. NOTE: Lubricate the coolant hoses with plain water only if needed. To install, reverse the removal procedure. 8. Fill the engine cooling system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 (V6-4.0L VIN K (2007)) 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 7528 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 (V6-4.0L VIN K (2007)) 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 7529 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 (V6-4.0L VIN K (2007)) 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 (V6-4.0L VIN K (2007)) 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 7535 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 (V6-4.0L VIN K (2007)) 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 7536 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core Heater Core: Service and Repair Heater Core HEATER CORE Removal and Installation NOTE: If a heater core leak is suspected, the heater core must be pressure leak tested before it is removed from the vehicle. 1. Remove the heater core and evaporator core housing. 2. Remove the 2 LH floor duct screws. 3. Remove the LH floor duct. 4. Remove the 2 RH floor duct screws. 5. Remove the RH floor duct. 6. Remove the 3 housing brace screws. 7. Remove the housing brace. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core > Page 7539 8. Remove the 3 heater tube cover screws. 9. Remove the heater tube cover. 10. Remove the heater tube seal. 11. Remove the 4 heater core cover screws. 12. Remove the heater core cover. 13. Remove the heater core. 14. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core > Page 7540 Heater Core: Service and Repair Auxiliary Heater Core AUXILIARY HEATER CORE Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core > Page 7541 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine coolant. 3. Release the 2 heater hose clamps and disconnect the heater hoses. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core > Page 7542 4. Remove the rear quarter trim panel. 5. Remove the 2 auxiliary line floorpan bracket nuts. 6. NOTE: The screw and line bracket are located inside the vehicle above the floorpan line bracket. Remove the 4 line bracket screws and the line bracket. 7. Disconnect the auxiliary harness electrical connector. 8. Remove the 2 auxiliary housing bolts and auxiliary housing nut. - To install, tighten to 6 Nm (53 lb-in). 9. Disconnect the 2 auxiliary actuator electrical connectors. 10. Remove the 3 auxiliary mode door actuator screws. 11. Remove the auxiliary mode door actuator. 12. Remove the 3 auxiliary temperature blend door actuator screws. 13. Remove the auxiliary temperature blend door actuator. 14. Remove the 4 heater core cover screws. 15. Remove the heater core cover. 16. Disconnect the 2 heater core hose clamps. 17. Remove the auxiliary heater core. 18. To install, reverse the removal procedure. - Lubricate the coolant hoses with plain water only if needed. 19. Fill the engine cooling system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 (V6-4.0L VIN K (2007)) 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 7551 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 (V6-4.0L VIN K (2007)) 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 7552 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 (V6-4.0L VIN K (2007)) 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 (V6-4.0L VIN K (2007)) 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 7558 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 (V6-4.0L VIN K (2007)) 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 7559 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 (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxiliary Heater Outlet and Inlet Line - Front Heater Hose: Service and Repair Auxiliary Heater Outlet and Inlet Line - Front AUXILIARY HEATER OUTLET AND INLET LINE - FRONT Removal and Installation 1. Remove the RH running board. 2. Drain the engine coolant. 3. Remove the RH rear wheel. 4. Release the front auxiliary heater line front clamps and disconnect the heater hoses. 5. Release the front auxiliary heater line rear clamps and disconnect the heater hoses. 6. Remove the 3 auxiliary line bracket nuts. - To install, tighten to 6 Nm (53 lb-in). 7. Remove the 3 auxiliary line bracket bolts. - To install, tighten to 6 Nm (53 lb-in). 8. Remove the 6 auxiliary line brackets. 9. Remove the front auxiliary heater outlet and inlet lines. 10. To install, reverse the removal procedure. 11. Fill the engine cooling system, Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxiliary Heater Outlet and Inlet Line - Front > Page 7562 Heater Hose: Service and Repair Auxiliary Heater Outlet and Inlet Line - Rear AUXILIARY HEATER OUTLET AND INLET LINE - REAR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine coolant. 3. Remove the spare tire. 4. Remove the 4 spare tire carrier bolts and the 2 spare tire carrier shield pin-type retainers. 5. Remove the spare tire carrier. 6. Release the 2 rear auxiliary heater line front hose clamps and disconnect the hoses. 7. Release the 2 rear auxiliary heater line rear hose clamps and disconnect the hoses. 8. Remove the 2 auxiliary line bracket nuts. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxiliary Heater Outlet and Inlet Line - Front > Page 7563 - To install, tighten to 8 Nm (71 lb-in). 9. Remove the 2 auxiliary line brackets. 10. Remove the rear auxiliary heater outlet line. 11. Remove the rear auxiliary heater inlet line. 12. To install, reverse the removal procedure. 13. Fill the engine cooling system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation High Pressure Safety Valve HVAC: Description and Operation A/C COMPRESSOR PRESSURE RELIEF VALVE An A/C compressor pressure relief valve is installed in the compressor to relieve unusually high refrigerant system discharge pressure buildups. The compressor pressure relief valve will avoid total refrigerant loss by closing after the excessive pressure has been relieved. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line Hose/Line HVAC: Service and Repair Compressor to Condenser Discharge Line COMPRESSOR TO CONDENSER DISCHARGE LINE Removal and Installation 1. Recover the refrigerant. 2. Remove the compressor-to-condenser discharge line bracket nut and detach the bracket. - To install, tighten to 7 Nm (62 lb-in). 3. Remove the compressor discharge fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (11 lb-ft). 4. Disconnect the A/C pressure transducer electrical connector. 5. Remove the condenser inlet fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). 6. Remove the compressor-to-condenser discharge line. 7. To install, reverse the removal procedure. - Install a new gasket seal and O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 7571 8. Evacuate, leak test and charge the refrigerant system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 7572 Hose/Line HVAC: Service and Repair Condenser to Evaporator Line CONDENSER TO EVAPORATOR LINE Removal and Installation NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the suction accumulator. All vehicles 1. Remove the air cleaner and air cleaner outlet tube. 2. Recover the refrigerant. 3. Remove the powertrain control module (PCM) and PCM bracket. 4. Disconnect the RH wheel speed sensor electrical connector and detach the wire harness from the condenser-to-evaporator line bracket. Vehicles equipped with 4.6L engine 5. Remove the suction accumulator-to-compressor line bracket nut. - To install, tighten to 7 Nm (62 lb-in). All vehicles 6. Disconnect the evaporator core orifice access fitting. - Discard the O-ring seal. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 7573 7. Remove the condenser-to-evaporator line bracket nut. - To install, tighten to 7 Nm (62 lb-in). 8. Remove the condenser outlet fitting nut and disconnect the fitting. - Discard the O-ring seal. - To install, tighten to 8 Nm (71 lb-in). 9. Disconnect the auxiliary evaporator inlet line fitting (if equipped). - Discard the O-ring seals. 10. Remove the front portion of the condenser-to-evaporator line. 11. Remove the A/C line bracket nut at the dash panel and detach the bracket. - To install, tighten to 6 Nm (53 lb-in). 12. Disconnect the evaporator inlet fitting. - Discard the O-ring seals. 13. Remove the rear portion of the condenser-to-evaporator line. 14. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 15. Evacuate, leak test and charge the refrigerant system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 7574 Hose/Line HVAC: Service and Repair Auxiliary Evaporator Outlet and Inlet Line - Front AUXILIARY EVAPORATOR OUTLET AND INLET LINE - FRONT Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 7575 Part 2 Removal and Installation NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the accumulator. 1. Recover the refrigerant. 2. Disconnect the front auxiliary evaporator inlet line front fitting. - Discard the O-ring seals. 3. Remove the RH running board. 4. Disconnect the front auxiliary evaporator outlet line front fitting. 5. Remove the RH rear wheel. 6. Remove the front auxiliary evaporator line fitting nuts and disconnect the fittings. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 7. Remove the 3 auxiliary line bracket nuts. - To install, tighten to 6 Nm (53 lb-in). 8. Remove the 3 auxiliary line bracket bolts. - To install, tighten to 6 Nm (53 lb-in). 9. Remove the 6 auxiliary line brackets. 10. Remove the front auxiliary evaporator outlet and inlet lines. 11. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 12. Evacuate, leak test and charge the refrigerant system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 7576 Hose/Line HVAC: Service and Repair Auxiliary Evaporator Outlet and Inlet Line - Rear AUXILIARY EVAPORATOR OUTLET AND INLET LINE - REAR Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor to Condenser Discharge Line > Page 7577 Part 2 Removal and Installation NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the accumulator. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the spare tire. 4. Remove the 4 spare tire carrier bolts and the 2 spare tire carrier shield pin-type retainers. 5. Remove the spare tire carrier. 6. Remove the 2 rear auxiliary evaporator line front fitting nuts and disconnect the fittings. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 7. Remove the 2 rear auxiliary evaporator line rear fitting nuts and disconnect the fittings. - Discard the O-ring seals. - To install, tighten to 8 Nm (71 lb-in). 8. Remove the auxiliary line bracket nut. - To install, tighten to 6 Nm (53 lb-in). 9. Remove the 2 auxiliary line brackets. 10. Remove the rear auxiliary evaporator outlet line. 11. Remove the rear auxiliary evaporator inlet line. - Discard the thermostatic expansion valve (TXV) filter. 12. To install, reverse the removal procedure. - Install new O-ring seals. - Install a new TXV filter. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 13. Evacuate, leak test and charge the refrigerant system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core and Evaporator Core Housing Housing Assembly HVAC: Service and Repair Heater Core and Evaporator Core Housing HEATER CORE AND EVAPORATOR CORE HOUSING Removal and Installation NOTE: - If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it is removed from the vehicle. - Installation of a new suction accumulator is not required when repairing the air conditioning system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the accumulator. - Lubricate the coolant hoses with plain water only if needed. 1. Recover the refrigerant. 2. Drain the engine coolant. 3. Remove the instrument panel. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core and Evaporator Core Housing > Page 7582 4. Detach the wiring harness bracket and position the harness aside. 5. Remove the heater tube bracket nut. 6. Remove the A/C line bracket nut at the dash panel. - To install, tighten to 11 Nm (8 lb-ft). 7. Disconnect the 2 heater hose clamps at the heater core. 8. Disconnect the evaporator inlet fitting. - Discard the O-ring seals. 9. Disconnect the evaporator outlet fitting. - Discard the O-ring seals. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core and Evaporator Core Housing > Page 7583 10. Disconnect the 2 vacuum connectors. 11. Detach the grommet and push the vacuum lines into the passenger compartment. 12. Remove the 4 heater core and evaporator core housing nuts. - To install, tighten to 9 Nm (80 lb-in). 13. Disconnect the ground terminal bolt. 14. Remove the heater core and evaporator core housing. 15. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 16. Fill and the engine cooling system. 17. Evacuate, leak test and charge the refrigerant system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core and Evaporator Core Housing > Page 7584 Housing Assembly HVAC: Service and Repair Plenum Chamber PLENUM CHAMBER Removal and Installation 1. Remove the instrument panel. 2. Remove the audio unit. 3. Remove the 3 plenum chamber screws. 4. Remove the instrument panel upper finish panel. 5. Remove the 3 defroster duct screws. 6. Remove the defroster duct. 7. Remove the plenum chamber. 8. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core and Evaporator Core Housing > Page 7585 Housing Assembly HVAC: Service and Repair Auxiliary Heater Core and Evaporator Core Housing AUXILIARY HEATER CORE AND EVAPORATOR CORE HOUSING Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core and Evaporator Core Housing > Page 7586 Removal and Installation NOTE: - Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the accumulator. - Clean and lubricate the coolant hoses with plain water only if needed. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Drain the engine coolant. 4. Remove the LH quarter trim panel. 5. Detach the headliner duct from the auxiliary climate control housing. 6. Remove the auxiliary evaporator inlet and outlet line fitting nuts. - Discard the O-ring seals. - Discard the thermostatic expansion valve (TXV) filter. - To install, tighten to 8 Nm (71 lb-in). 7. Release the heater hose clamps and disconnect the heater hoses. - After disconnecting the heater hoses, allow any residual coolant to drain from the auxiliary heater core to avoid coolant spilling inside the passenger compartment. 8. Remove the 2 auxiliary line floorpan bracket nuts. - To install, tighten to 8 Nm (71 lb-in). 9. Remove the 2 auxiliary heater core and evaporator core housing bolts. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core and Evaporator Core Housing > Page 7587 - To install, tighten to 6 Nm (53 lb-in). 10. Remove the auxiliary heater core and evaporator core housing nut. - To install, tighten to 6 Nm (53 lb-in). 11. Disconnect the auxiliary harness electrical connector. 12. Remove the auxiliary heater core and evaporator core housing. 13. To install, reverse the removal procedure. - Clean and lubricate the coolant hoses with plain water only if needed. - Install new O-ring seals. - Install a new TXV filter. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 14. Fill the engine cooling system. 15. Evacuate, leak test and charge the refrigerant system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Item....................................................................................................................................................... ..............................................................Specification Refrigerant Capacity Capacity without auxiliary climate control............................................................................................. ......................................................0.88 kg (31 oz) Capacity with auxiliary climate control................... .....................................................................................................................................1.33 kg (47 oz) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 7592 Refrigerant: Fluid Type Specifications Item....................................................................................................................................................... ..............................................................Specification Refrigerant Type R134a Refrigerant YN-19 .................................................................................................................... .................................................. WSH-M17B19-A Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 7593 Refrigerant: Description and Operation REFRIGERANT SYSTEM DYE Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in refrigerant system leak diagnosis using a Rotunda-approved ultraviolet blacklight. It is not necessary to add additional dye to the refrigerant system before diagnosing leaks, even if a significant amount of refrigerant has been removed from the system. Replacement suction accumulators are shipped with a fluorescent dye "wafer" included in the desiccant bag which will dissolve after approximately 30 minutes of continued A/C operation. It is not necessary to add dye after flushing or filtering the refrigerant system because a new suction accumulator is installed as part of the flushing or filtering procedure. Additional refrigerant system dye should only be added if more than 50% of the refrigerant system lubricant capacity has been lost due to a fitting separation, hose rupture or other damage. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Item....................................................................................................................................................... ..............................................................Specification Refrigerant Oil Capacity Capacity without auxiliary climate control............................................................................................. ......................................................266 ml (9 fl oz) Capacity with auxiliary climate control................... ...................................................................................................................................473 ml (16 fl oz) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 7598 Refrigerant Oil: Fluid Type Specifications Item....................................................................................................................................................... ..............................................................Specification Refrigerant Oil Type PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D ............................................................................................................. WSH-M1C231-B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations View 151-2 (Engine Compartment - 4.0L, (2 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7603 C1078 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Motor Relay 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Motor Relay 1 > Page 7609 View 151-27 (Front HVAC) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 7610 C2017 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay 1 > Page 7613 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 7617 Compressor Clutch Relay: Description and Operation AIR CONDITIONING (A/C) CLUTCH RELAY (A/CCR) NOTE: The PCM PIDs WAC and wide open throttle air conditioning cutoff fault (WACF) are used to monitor the A/CCR output. The A/CCR is wired normally open. There is no direct electrical connection between the A/C switch or electronic automatic temperature control (EATC) module and the A/C clutch. The PCM receives a signal indicating that A/C is requested. For some applications, this message is sent through the communications network. When A/C is requested, the PCM checks other A/C related inputs that are available, such as A/C pressure switch and A/C cycling switch. If these inputs indicate A/C operation is OK, and the engine conditions are OK (coolant temperature, engine RPM, throttle position), the PCM grounds the A/CCR output, closing the relay contacts and sending voltage to the A/CCR. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 7618 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Page 7622 Control Module HVAC: Diagrams C228A C228B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > System Relay, HVAC > Component Information > Locations View 151-15 (Left Rear, (1 0f 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > System Relay, HVAC > Component Information > Locations > Page 7626 C3023 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > System Relay, HVAC > Component Information > Locations > Page 7627 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Locations View 151-30 (Steering Wheel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Locations > Page 7632 C2208 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations View 151-2 (Engine Compartment - 4.0L, (2 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7636 C132 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7637 Ambient Temperature Sensor / Switch HVAC: Service and Repair AMBIENT AIR TEMPERATURE SENSOR Removal and Installation Mountaineer 1. Remove the radiator grille. 2. Remove the pin-type retainers and position the air deflector forward. 3. Remove the 2 air deflector pin-type retainers and detach the air deflector from the 2 locator pins on the radiator support. All vehicles 4. Detach the ambient air temperature sensor electrical connector. 5. Remove the ambient air temperature sensor. 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations View 151-28 (Front HVAC) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 7641 C271 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 7642 Blower Motor Switch: Service and Repair BLOWER MOTOR SPEED CONTROL Removal and Installation 1. Remove the blower motor speed control screw. 2. Remove the blower motor speed control. 3. Disconnect the blower motor speed control electrical connector. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 7646 C233 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 7647 Cabin Temperature Sensor / Switch: Service and Repair IN-VEHICLE TEMPERATURE SENSOR Removal and Installation 1. Remove the instrument cluster finish panel. 2. Remove the in-vehicle temperature sensor. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation Evaporator Temperature Sensor / Switch: Description and Operation AIR CONDITIONING EVAPORATOR TEMPERATURE (ACET) SENSOR A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance The ACET sensor measures the evaporator air discharge temperature. The ACET sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The PCM sources a low current 5 volts on the ACET circuit. With SIG RTN also connected to the ACET sensor, the varying resistance changes the voltage drop across the sensor terminals. As A/C evaporator air temperature changes, the varying resistance of the ACET sensor changes the voltage the PCM detects. The ACET sensor is used to more accurately control A/C clutch cycling, improve defrost/demist performance, and reduce A/C clutch cycling. NOTE: These values can vary 15% due to sensor and VREF variations. Voltage values were calculated for VREF equals 5.0 volts. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations View 151-2 (Engine Compartment - 4.0L, (2 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7655 C1078 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations View 151-11 (behind Dash Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 7659 C286 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and Operation Service Port HVAC: Description and Operation SERVICE GAUGE PORT VALVES The high-pressure service gauge port valve is located on the compressor-to-condenser discharge line. The low-pressure service gauge port valve is located on the suction accumulator. 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 very small amount of leakage will always be detectable around the Schrader-type valve with the service gauge port valve cap removed, and is considered normal. A new Schrader-type valve core can be installed if the seal leaks excessively. - The service gauge port valve caps are used as primary seals in the refrigerant system to prevent leakage through the Schrader-type valves from reaching the atmosphere. Always install and tighten the A/C service gauge port valve caps to the correct torque after they are removed. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations View 151-11 (behind Dash Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Page 7666 C286 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > System Relay, HVAC > Component Information > Locations View 151-15 (Left Rear, (1 0f 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > System Relay, HVAC > Component Information > Locations > Page 7670 C3023 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > System Relay, HVAC > Component Information > Locations > Page 7671 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service and Repair Vacuum Harness HVAC: Service and Repair VACUUM HOSE REPAIR - MINI-TUBE Special Tool(s) Special 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 in) 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. WARNING: Read the warning information on the product label to prevent possible personal injury. 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. 5. Insert the ends of the mini-tube vacuum hose approximately 9 mm (3/8 in) into the ends of the standard 1/8-inch repair vacuum hose. 6. Shake the repair 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 pump or equivalent. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Service and Repair Vacuum Reservoir HVAC: Service and Repair VACUUM RESERVOIR Removal and Installation 1. Remove the vacuum reservoir screw. 2. Remove the vacuum reservoir. 3. Disconnect the vacuum connector. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Solenoid Valve HVAC > Component Information > Locations View 151-11 (behind Dash Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Solenoid Valve HVAC > Component Information > Locations > Page 7681 C2093 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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: Remove restraint system diagnostic tools from the vehicle prior to road testing. If tools are not removed, the supplemental restraint system (SRS) device may not deploy in a crash. Failure to follow this instruction may result in serious personal injury or death in a crash and possibly violate vehicle safety standards. NOTE: After diagnosing or repairing a supplemental restraint system (SRS), the restraint system diagnostic tools (if required) must be removed before operating the vehicle over the road. NOTE: Deployable devices (such as air bag modules, pretensioners) may deploy alone or in various combinations depending on the impact event. NOTE: Always refer to the appropriate workshop manual procedures prior to carrying out vehicle repairs affecting the SRS and safety belt system. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. NOTE: Refer to the correct removal and installation procedure for all SRS components being installed. When any deployable device or combination of devices are deployed and/or the restraints control module (RCM) has the DTC B1231 (Event Threshold Exceeded) in memory, the repair of the vehicle's SRS is to include the removal of all deployed devices and the installation of new deployable devices, the removal and installation of new impact sensors, and the removal and installation of a new RCM. DTCs must cleared from all required modules after repairs are carried out. Vehicles with occupant classification sensor (OCS) system 2. NOTE: After installation of new occupant classification sensor (OCS) system components carry out the OCS System Reset procedure as instructed in the workshop manual. Refer to the appropriate workshop manual for OCS system removal and installation procedure. When a vehicle has been involved in a collision and the occupant classification system module (OCSM) has DTC B1231 stored in memory, the repair of the OCS system is to include the following procedures for the specified system: - For rail type OCS system, inspect the passenger side floorpan for damage and repair as necessary. Install new OCS system rails. - For weight sensor bolt type OCS system, inspect the passenger side floorpan for damage and repair as necessary. Install a new seat track with OCS system weight sensor bolts. DTC must be cleared from the OCSM before carrying out Occupant Classification Sensor (OCS) System Reset. Do not install a new OCSM unless DTC B1231 cannot be cleared. - NOTE: Most bladder type OCSM do not store a DTC B1231 in memory after deployment. The DTC B1231 is stored only by the RCM. For bladder type OCS system, inspect for damage and repair as necessary. If installation of an OCS system component is required, an OCS system service kit must be installed. All vehicles 3. 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. 4. When the driver air bag module has deployed, a new clockspring must be installed. 5. New driver and/or front passenger safety belt systems (including retractors, buckles and height adjusters) must be installed if the vehicle is involved in a collision that results in deployment of the driver and/or front passenger safety belt pretensioners. For additional information, refer to Safety Belt System. 6. Inspect the entire vehicle for damage, including the following components: Steering column (deployable column if equipped) 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. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 7687 SRS wiring, wiring harnesses and connectors 7. 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 (V6-4.0L VIN K (2007)) 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 7688 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, belt tension sensor [BTS], if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after every collision. All 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 new assemblies installed if either damage or incorrect operation is noted. Failure to follow these instructions could increase the risk of personal injury in collisions. 1. Before installing a 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 worked back to its original shape and structural integrity. 2. Install the new safety belt(s). Carry out the Functional Test. See: Seat Belt Systems/Testing and Inspection/Component Tests and General Diagnostics Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Depowering and Repowering SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING Special Tool(s) Special Tool(s) Depowering 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. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the electrical connector on a safety canopy module. Doing so can result in safety canopy deployment. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a SRS component is being serviced, the SRS must be depowered. - 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. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box (SJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse 17 (10A) from the SJB. 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 switch to OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or installing any front or side air bag supplemental restraint system (SRS) components and before servicing, installing, 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 front impact severity sensors are located on the radiator support bracket above the lower front splash shield. The front door side impact sensors are located in the first row doors, behind the door trim panel. The C-pillar side impact sensors (if equipped) are located on the C-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). Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7694 remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install RCM fuse 17 (10A) to the SJB and close the cover. 4. 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. 5. Prove out the SRS as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch 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 6 seconds and then turn off. If an air bag SRS fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag indicator might not light 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 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 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous diagnostic trouble codes (DTCs) from the RCM and occupant classification sensor (OCS) module using a scan tool. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7695 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Deactivation and Reactivation SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION Special Tool(s) Special Tool(s) Deactivation 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. - Never probe the connectors on the safety canopy module. Doing so can result in safety canopy deployment, which can result in personal injury. - The safety belt pretensioner and adaptive load limiting retractor are pyrotechnic devices. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner/adaptive load limiting retractor. Never probe a pretensioner or adaptive load limiting retractor electrical connector. Doing so could result in pretensioner, adaptive load limiting retractor or air bag deployment and could result in personal injury. - 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a SRS component is being serviced, the SRS must be depowered. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7696 - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a SRS fault. - 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 smart junction box (SJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse 17 (10A) from the SJB. 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 front impact severity sensors are located on the radiator support bracket above the lower front splash shield. The front door side impact sensors are located in the first row doors, behind the door trim panel. The C-pillar side impact sensors (if equipped) are located on the C-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). Disconnect the battery ground cable and wait at least one minute. 7. Remove the 2 driver air bag module bolts (1 shown). 8. NOTE: Note the position of the 3 driver air bag module wiring connectors for installation. Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag module. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7697 9. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of the steering column. 10. Open and lower the glove compartment door. 11. Detach the wiring retainer, remove the 4 bolts and the passenger air bag module heat shield. 12. NOTE: Deactivate the passenger air bag module as shown, the canister vent and adaptive tether squibs do not require deactivation. Through the glove compartment opening, disconnect the LH side passenger air bag module electrical connector. 13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector on the LH side. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7698 14. From under the rear of the passenger seat, detach the passenger seat side air bag module electrical connector from the seat track bracket. Then slide and disengage the passenger seat side air bag module electrical connector locking clip, and then release the tab and disconnect the passenger seat side air bag module electrical connector. 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat side air bag module electrical connector. Vehicles without safety canopy modules 16. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy bridge resistor from the safety canopy electrical connector. If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the RCM. If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low resistance fault will be generated by the RCM. Explorer and Mountaineer vehicles with safety canopy modules 17. Release and position aside the passenger side C-pillar trim panel. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7699 18. Disconnect the passenger side safety canopy module electrical connector. 19. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. 20. Release and position aside the driver side C-pillar trim panel. 21. Disconnect the driver side safety canopy module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7700 22. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. Explorer Sport Trac vehicles with safety canopy modules 23. Remove the driver and passenger side upper C-pillar trim panels. 24. Disconnect the passenger side safety canopy module electrical connector. 25. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. 26. Disconnect the driver side safety canopy module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7701 27. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. All vehicles 28. From under the rear of the driver seat, slide and disengage the driver seat side air bag module electrical connector locking clip, and then release the tab and disconnect the driver seat side air bag module electrical connector. 29. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air bag module electrical connector. 30. Install the RCM fuse 17 (10A) to the SJB. 31. Connect the battery ground cable. Reactivation All vehicles 1. Remove the RCM fuse 17 (10A) from the SJB. 2. Disconnect the battery ground cable and wait at least one minute. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7702 3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat side air bag module electrical connector. 4. Connect the driver seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Explorer Sport Trac vehicles with safety canopy modules 5. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 6. Connect the driver side safety canopy module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7703 7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 8. Connect the passenger side safety canopy module electrical connector. 9. Install the driver and passenger upper C-pillar trim panels. Explorer and Mountaineer vehicles with safety canopy modules 10. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 11. Connect the driver side safety canopy module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7704 12. Install the driver side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. 13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 14. Connect the passenger side safety canopy module electrical connector. 15. Install the passenger side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. All vehicles Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7705 16. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat side air bag module electrical connector. 17. Connect the passenger seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Then attach the passenger seat side air bag module electrical connector to the seat track bracket. 18. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector on the LH side. 19. Connect the LH side passenger air bag module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7706 20. Install the passenger air bag module heat shield and the 4 bolts. Attach the wiring retainer. 21. Close glove compartment door. 22. Remove the restraint system diagnostic tools from the clockspring electrical connectors at the top of the steering column. 23. CAUTION: The clockspring electrical connectors are unique and cannot be connected to the driver air bag module in the wrong position. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Connect the driver air bag module electrical connectors as noted in removal. 24. Install the 2 driver air bag module bolts (1 shown). - Tighten to 7 Nm (62 lb-in). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7707 25. 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. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 26. Turn the ignition switch from OFF to ON. 27. Install the RCM fuse 17 (10A) to the SJB and install the cover. 28. 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. 29. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the switch 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 6 seconds and then turn off. If an air bag SRS fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag indicator might not light 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 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 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and occupant classification sensor (OCS) module using a scan tool. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Side Air Bag Module, Left View 151-19 (Driver Seat) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Side Air Bag Module, Left > Page 7712 View 151-20 (Passenger Seat) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Side Air Bag Module, Left > Page 7713 View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Unit 1 C216A Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Unit 1 > Page 7716 C216B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Unit 1 > Page 7717 C216C Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Unit 1 > Page 7718 C2351 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Unit 1 > Page 7719 Air Bag: Diagrams C216A C216B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Unit 1 > Page 7720 C216C C2351 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Unit 1 > Page 7721 C367 C337 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Unit 1 > Page 7722 C256 C3213 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Unit 1 > Page 7723 C3214 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Driver and Passenger Air Bag Module Air Bag: Description and Operation Driver and Passenger Air Bag Module Driver Air Bag Module The driver air bag module: contains dual stage deployment (advanced restraint system). - is equipped with canister vent. - is installed new as an assembly. - is mounted in the center of the steering wheel. In addition to dual stage deployment (advanced restraint system) driver air bag module, this vehicle is equipped with a driver air bag canister vent. Canister venting is a deployable device integrated to the driver air bag module. Canister venting controls the inflation rate of the driver air bag, and the escape rate of gases from the vent. Passenger Air Bag Module The passenger air bag module: contains dual stage deployment (advanced restraint system). - is equipped with canister vent. - is equipped with adaptive tether. - is installed new as an assembly. - is mounted in the passenger side of the instrument panel. Passenger Air Bag Module In addition to dual stage deployment (advanced restraint system) front passenger air bag module, this vehicle is equipped with a passenger air bag adaptive tether as well as a passenger air bag canister vent. Canister venting is a deployable device integrated to the passenger air bag module. Canister venting controls the inflation rate of the passenger air bag, and the escape rate of gases from the vent. Adaptive tether is a deployable device integrated to the passenger air bag module. Adaptive tether restricts the rearward movement of the passenger air bag. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Driver and Passenger Air Bag Module > Page 7726 Air Bag: Description and Operation Safety Canopy Module SAFETY CANOPY MODULE WARNING: Anytime the safety canopy has deployed, the headliner, and all A-, B-, C- and D-pillar (Explorer/Mountaineer) upper trim panels and attaching hardware must be replaced along with any other damaged components and hardware. Failure to do so can result in personal injury in the event of a safety canopy deployment. The safety canopy module: - is installed as an assembly. - is mounted above the headliner. - attaches from the A-pillar frame to the D-pillar frame on Explorer/Mountaineer and from the A-pillar frame to the C-pillar frame on Explorer Sport Trac. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module Air Bag: Service and Repair Driver Air Bag Module DRIVER 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 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. - To reduce the risk of personal injury, do not use any memory saver devices. 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. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7729 1. Depower the system. 2. Remove the 2 driver air bag module bolts. - To install, tighten to 7 Nm (62 lb-in). 3. CAUTION: The clockspring electrical connectors are unique and cannot be installed in the wrong position on the driver air bag module. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. NOTE: Note the position of the locator holes in the back of the driver air bag module and locator tabs on the steering wheel for installation. Disconnect the 3 electrical connectors and remove the drivers air bag module. 4. To install, reverse the removal procedure. 5. Repower the system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7730 Air Bag: Service and Repair Passenger Air Bag Module PASSENGER AIR BAG MODULE Removal and 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 deployment door 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 deployment door 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 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7731 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 deployment doors must be replaced, not repainted. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. Depower the system. 2. Open and lower the glove compartment door. 3. Release the wiring retainer, then remove the 4 bolts and the passenger air bag module heat shield. 4. Through the glove compartment opening, disconnect the 2 passenger air bag module electrical connectors. 5. Through the glove compartment opening, remove the 4 air bag module nuts. - To install, tighten to 9 Nm (80 lb-in). 6. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Through the glove compartment opening, push up to release the deployment door clips from the instrument panel (I/P) and push the passenger air bag module out of the I/P and remove. 7. NOTE: During air bag module installation, make sure all the deployment door clips are fully seated into the I/P. To install, reverse the removal procedure. 8. Repower the system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7732 Air Bag: Service and Repair Safety Canopy Module SAFETY CANOPY MODULE Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7733 Part 2 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. - To reduce the risk of personal injury from an accidental deployment, always carry or place a live safety canopy module with the safety canopy and tear seam pointed away from your body. Failure to do so can result in personal injury in the event of a safety canopy module deployment. - Anytime the safety canopy has deployed, the headliner, and all A-, B-, C and D-pillar, upper trim panels and attaching hardware must be installed new along with any other damaged components and hardware. Failure to do so can result in personal injury in the event of a safety canopy deployment. - Vehicles equipped with safety canopy modules require a specific headliner. When installing a new headliner on a vehicle equipped with safety canopy modules, make sure a headliner for safety canopy modules is being used. The word "AIRBAG" will appear on the headliner where it meets each B-pillar trim panel. Failure to do so can result in personal injury in the event of a safety canopy module deployment. - Before installing a safety canopy module, inspect the roof line for any damage. If necessary, the sheet metal must be reworked to its original condition and structural integrity. All damaged fasteners must be installed new and any foreign material removed. Failure to do so may result in personal injury in the event of a safety canopy deployment. - Inspect the safety canopy before installation. If the safety canopy is damaged or the cover has separated and the canopy material has been exposed, a new safety canopy module must be installed. Do not attempt to repair the safety canopy module. Failure to follow these instructions can result in personal injury in the event of a safety canopy module deployment. - To reduce the risk of injury, do not obstruct or place objects in the deployment path of the safety canopy module. Failure to follow these instructions can result in personal injury in the event of a safety canopy module deployment. - Never put any type of fastener or tie strap around any part of the safety canopy module or interior trim panel. This will prevent the safety canopy module from deploying correctly. Failure to do so can result in personal injury in the event of a safety canopy module deployment. - Never probe the electrical connector on a safety canopy module. Doing so can result in safety canopy deployment. - To reduce the risk of personal injury, do not use any memory saver devices. - The safety canopy must be installed in the vehicle using new torque-prevailing type J-nuts (W520822, 9 per side). Use of this J-nut is mandatory so as to reduce the risk of loss of fastener effectiveness. Failure to follow these instructions may result in personal injury in the event of a safety canopy deployment. NOTE: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a SRS fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - RH side safety canopy module shown, LH side similar. All vehicles 1. Depower the system. 2. Remove the headliner. Vehicles with auxiliary climate control Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7734 3. Remove the 2 retainers and the auxiliary climate control headliner duct from the C-pillar. All vehicles 4. NOTE: Note the position and wire routing of the safety canopy module wiring harness for installation. Disconnect the safety canopy module electrical connector and detach the connector and wiring pin-type retainers from the C-pillar. Vehicles with moonroof 5. NOTE: Note the position of the 2 rear moonroof drain hose routing clips for installation. Disconnect the rear moonroof drain tube and detach the 2 rear moonroof drain hose routing clips. Vehicles with entertainment system 6. NOTE: Note the position and routing of the entertainment system wiring for installation. Detach the 2 entertainment system wiring retainers and position wiring aside. All vehicles 7. NOTE: Note the locator tab on the front tether anchor bracket to the A-pillar sheet metal for installation. Remove the bolt and the front tether anchor bracket. 8. Detach the 3 safety canopy module front tether pin-type retainers from the A-pillar. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7735 9. Remove the safety canopy module front 2 bolts. 10. Remove the 2 bolts and the safety canopy module C-pillar tether bracket. 11. Remove the safety canopy module 3 bolts near the C-pillar. 12. Remove the safety canopy module 2 rear bracket bolts. 13. Remove the safety canopy module bolt at the B-pillar. 14. Gently lift the safety canopy module up and inward at the B-pillar to release the bracket hook from the sheet metal. 15. Move the safety canopy module forward to release the rear bracket hook from the sheet metal and remove the safety canopy module. Installation WARNING: - Before installing a safety canopy module, inspect the roof line for any damage. If necessary, the sheet metal must be reworked to its original condition and structural integrity. All damaged fasteners must be installed new and any foreign material removed. Failure to do so may result in personal injury in the event of a safety canopy deployment. - Inspect the safety canopy before installation. If the safety canopy is damaged or the cover has separated and the canopy material has been exposed, a new safety canopy module must be installed. Do not attempt to repair the safety canopy module. Failure to follow these instructions can result in personal injury in the event of a safety canopy module deployment. - Never put any type of fastener or tie strap around any part of the safety canopy module or interior trim panel. This will prevent the safety canopy module from deploying correctly. Failure to do so can result in personal injury in the event of a safety canopy module deployment. - The safety canopy must be installed in the vehicle using new torque-prevailing type J-nuts (W520822, 9 per side). Use of this J-nut is mandatory so as to reduce the risk of loss of fastener effectiveness. Failure to follow these instructions may result in personal injury in the event of a safety canopy deployment. All vehicles Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7736 1. Remove the 4 front J-nuts and install new. 2. Remove the 5 rear J-nuts and install new. 3. Position safety canopy module by moving it rearward installing the rear bracket hook in the sheet metal. 4. Install the safety canopy module B-pillar bracket hook in the sheet metal. 5. NOTE: Make sure all safety canopy module bolt holes line up with all J-clips. Install the safety canopy module front 2 bolts with the forward most bolt first. Tighten to 8 Nm (71 lb-in). 6. Install the safety canopy module B-pillar bolt. - Tighten to 8 Nm (71 lb-in). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7737 7. Install the 3 C-pillar safety canopy module bolts. - Tighten to 8 Nm (71 lb-in). 8. Install the 2 safety canopy module rear bracket bolts. - Tighten to 8 Nm (71 lb-in). 9. Install the safety canopy module C-pillar tether bracket and the 2 bolts. - Tighten to 12 Nm (9 lb-ft). 10. Attach the 3 safety canopy module front tether pin-type retainers to the A-pillar. 11. NOTE: Make sure the safety canopy module front tether bracket locator tab is correctly installed in the A-pillar sheet metal. Install the safety canopy module front tether bracket and bolt. Tighten to 8 Nm (71 lb-in). Vehicles with entertainment system 12. NOTE: Make sure to route the entertainment system wiring as noted during removal. Attach the 2 entertainment system wiring retainers. Vehicles with moonroof 13. NOTE: Make sure to route the moonroof drain hose as noted during removal. Connect the rear moonroof drain tube and attach the 2 rear moonroof drain hose clips. All vehicles 14. NOTE: Make sure to route the safety canopy module wiring harness as noted during removal. Connect the safety canopy module electrical connector and attach the connector and wiring pin-type retainers to the C-pillar. Vehicles with auxiliary climate control Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Driver Air Bag Module > Page 7738 15. Install the auxiliary climate control headliner duct and 2 retainers to the C-pillar. All vehicles 16. Install the headliner. 17. Repower the system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs Air Bag Control Module: Technical Service Bulletins Restraints - Control Module DTCs & Associated Fault PIDs TSB 07-12-3 06/25/07 RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS) - SERVICE TIPS FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred, Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar 2005-2007 Escape Hybrid, Escape 2007 E-Series LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator 2003-2007 Navigator 2006-2007 Mark LT MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan 2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 07-7-8 to update the vehicle application. ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most 2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS) terminology and navigation which does not translate well when using Integrated Diagnostic System (IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS). ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool being used. SERVICE TIPS DTCs And Associated Fault PIDs Description Many of the continuous memory and on-demand DTCs that can be present in the RCM provide general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional DTCs. Conventional DTCs identify a specific concern for a given component and point to a particular diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7743 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7744 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7745 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7746 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7747 DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s) or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the specific device and fault condition. Fault PIDs are available for both on-demand (active) and continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures 1-5) VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools have transitioned. Examples of how the WSM may direct you to view fault PIDs are: ^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7748 ^ View and Record DTC XXXXX Fault PIDs (2007 WSM) ^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs) In each instance the direction is the same (view fault PIDs to identify the specific component and fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology, will vary. FLAG the DTC - View the Fault PIDs For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is necessary to view the fault PIDs from DataLogger. Using IDS/PDS NOTE WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS, HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION. 1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous memory DTCs. 2. To view the fault PIDs associated with an on-demand DTC: a. Toolbox b. DataLogger c. Modules d. RCM 3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". ^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads "FAULT' indicating a front internal crash sensor fault. 4. To view the fault PIDs associated with a continuous memory DTC: a. Toolbox b. DataLogger c. Modules d. RCM 5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads "FAULT" indicating a front internal crash sensor fault. IDS/PDS Fault PID Naming Conventions The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example, the fault PIDs 2296_18_OD and 2296_18_CM break down as follows: ^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation. ^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC. ^ OD - Identifies the fault PID as an on-demand fault. ^ CM - Identifies the fault PID as a continuous memory (intermittent) fault. NOTE THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON VEHICLE EQUIPMENT. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7749 Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5) WARRANTY STATUS: Information Only Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 7750 Air Bag Control Module: Locations View 151-12 (Center Console) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 7751 View 151-13 (Left Front) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 7752 Air Bag Control Module: Diagrams C310A Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 7753 C310B (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 7754 C310B (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 7755 Air Bag Control Module: Description and Operation RESTRAINTS CONTROL MODULE (RCM) WARNING: - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, a new RCM must be installed whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. CAUTION: When installing a new RCM on vehicles built 7/31/06 or after, it is necessary to carry out programmable module installation (PMI). NOTE: When installing a new RCM, always make sure the correct RCM is being installed. If an incorrect RCM is installed, erroneous DTCs will result. The RCM carries out the following functions: - deploys the air bag(s) in the event of a deployable crash. - activates the safety belt buckle pretensioner and safety belt adaptive load limiting retractor to control tension on the safety belt. - monitors the SRS for faults. - requests the illumination of the air bag indicator if a fault is detected. - communicates through the DLC the on-demand or continuous DTCs. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the ON position, the RCM will request illumination of 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 6 seconds and then off. If a SRS fault exists, the air bag indicator will illuminate and remain illuminated for the rest of the key cycle. The RCM will also communicate the on-demand (current) and continuous (historical) DTCs through the DLC, to the scan tool. If the RCM requests illumination of the air bag indicator and the air bag indicator does not function, the instrument cluster module will automatically activate an audible chime. The chime is a series of 5 sets of 5 tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. 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 lost or damaged during impact. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 7756 Air Bag Control Module: Service and Repair RESTRAINTS CONTROL MODULE (RCM) Special Tool(s) Special Tool(s) Removal WARNING: - Always wear safety glasses when repairing an air bag SRS vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - The RCM orientation is critical for correct air bag supplemental restraint system (SRS) operation. If a vehicle equipped with an SRS system has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the RCM must be installed new whether or not the air bags have deployed. In addition, make sure the area of Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 7757 the RCM mounting is restored to its original condition. - Vehicle sensor orientation is critical for correct 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. Install a new sensor and correctly position the sensor or any other damaged SRS components whether or not the air bag is deployed. - The tightening torque of the air bag RCM retaining nuts is critical for correct system operation. - To reduce the risk of personal injury, do not use any memory saver devices. CAUTION: - Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. - When installing a new RCM on vehicles built 7/31/06 or after, it is necessary to carry out programmable module installation (PMI). See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning NOTE: - When installing a new RCM, always make sure the correct RCM is being installed. If an incorrect RCM is installed, erroneous DTCs will result. - 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 SRS fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. Vehicles built 7/31/06 or after 1. Carry out the steps necessary to prepare for programmable module installation (PMI). All vehicles 2. Depower the system. 3. Remove the floor console. 4. Disconnect the large restraints control module (RCM) electrical connector. 1 Pinch the thumb tab and pivot the large RCM electrical connector position assurance lever all the way back until it stops. 2 Pull out and disconnect the large RCM electrical connector. 5. Press to release the locking tab and disconnect the small RCM electrical connector. 6. Remove the 3 RCM nuts. 7. Remove the RCM. Installation All vehicles 1. Install the RCM. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 7758 2. Install the 3 RCM nuts. - Tighten to 12 Nm (9 lb-ft). 3. Connect the small RCM electrical connector. 4. NOTE: The RCM has been removed for clarity. On the large RCM electrical connector, place the connector position assurance lever in the full release position. 5. CAUTION: Putting the large RCM electrical connector into the RCM on an angle can cause bad electrical connections and damage components. Position the large RCM electrical connector into the RCM. 6. Connect the large RCM connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 7759 - CAUTION: Do not push the connector on to where the lever pivots and seats itself. Light pressure is needed to get the connector into position on the RCM before using the lever to fully seat the connector. With the large RCM electrical connector uniformly aligned to the RCM, lightly push in until a subtle audible click is heard and a slight resistance is felt. - Using the connector position assurance lever, pivot it toward the RCM, drawing the connector into the RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place. 7. Install the floor console. 8. Repower the system. Do not prove out the SRS at this time. Vehicles built 7/31/06 or after 9. Carry out the steps necessary to complete PMI. All vehicles 10. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch 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 6 seconds and then turn off. If an air bag SRS fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag indicator might not light 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 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 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous diagnostic trouble codes (DTCs) from the RCM and occupant classification sensor (OCS) module using a scan tool. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Indicator > Component Information > Diagrams C2286 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Indicator > Component Information > Diagrams > Page 7763 Air Bag Deactivation Indicator: Description and Operation PASSENGER AIR BAG DEACTIVATION (PAD) INDICATOR The passenger air bag deactivation (PAD) indicator is a visual indicator used to inform the front seat occupants of the passenger air bag deactivation state. The PAD indicator is a stand-alone lamp installed into the vehicle instrument panel in a position visible to each front seat occupant. The RCM controls the state of the PAD indicator through a direct hardware connection, based on information provided by the occupant classification sensor (OCS) system. The PAD indicator is lit to indicate the passenger air bag module is disabled. An exemption to this is when the front passenger seat is determined to be empty and passenger safety belt buckle unbuckled, and therefore indication of a deactivated passenger air bag module is not necessary. In all other cases, the PAD indicator is unlit when the passenger air bag module is enabled. When the ignition switch is in the ON position, the PAD indicator prove-out period is initiated by the RCM. The RCM briefly activates the PAD indicator to prove-out the indicator function and verify to the front occupants correct functional operation of the PAD indicator. The PAD indicator will be lit/unlit within 1.0 to 1.5 seconds of a change of state from the OCS system. When an OCS system fault is present, the RCM defaults the passenger air bag module to the last valid state received from the OCS system until the ignition switch is turned OFF. If the OCS system fault is still present when the ignition switch is turned ON, the RCM defaults the passenger air bag module to enabled regardless of the size of occupant in the front passenger seat. The PAD indicator will be unlit. Passenger Air Bag And PAD Indicator Status The above table indicates the passenger air bag status and the PAD indicator status based the size of the front outboard passenger occupant Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Indicator > Component Information > Diagrams > Page 7764 Air Bag Deactivation Indicator: Service and Repair PASSENGER AIR BAG DEACTIVATION (PAD) INDICATOR Removal and 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. Depower the system. 2. Remove the floor console. 3. Gently pull outward to release the clips on the instrument panel center finish panel. 4. Disconnect the passenger air bag deactivation (PAD) indicator electrical connector. 5. Remove the 2 screws and remove the PAD indicator. 6. To install, reverse the removal procedure. 7. Repower the system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Resistor > Component Information > Description and Operation Air Bag Resistor: Description and Operation SAFETY CANOPY BRIDGE RESISTOR CAUTION: Do not deactivate the driver safety canopy module circuit by removing the bridge resistor from the electrical connector. If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low resistance fault will be generated. The safety canopy bridge resistor: - is equipped on vehicles without safety canopy modules. - must not be removed during deactivation. - is located on the LH side D-pillar, behind the trim panel on Explorer/Mountaineer and on the LH side C-pillar, behind the trim panel on Explorer Sport Trac. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Resistor > Component Information > Description and Operation > Page 7768 Air Bag Resistor: Service and Repair SAFETY CANOPY BRIDGE RESISTOR Removal and 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a SRS fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. Depower the system. 2. Release the LH rear door weather-stripping near the C-pillar trim panel. 3. Detach and position aside the LH C-pillar trim panel. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Resistor > Component Information > Description and Operation > Page 7769 4. Disconnect the electrical connector and remove the safety canopy module bridge resistor. 5. To install, reverse the removal procedure. 6. Repower the system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams Clockspring Assembly / Spiral Cable: Diagrams C218A C218B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 7773 Clockspring Assembly / Spiral Cable: Description and Operation CLOCKSPRING The clockspring: - is mounted on the steering column, behind the steering wheel. - continuously transfers electrical signals from the driver air bag module to the RCM. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 7774 Clockspring Assembly / Spiral Cable: Service and Repair CLOCKSPRING 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. - To reduce the risk of personal injury, do not use any memory saver devices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 7775 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. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. Depower the system. 2. Make sure the road wheels are in the straight-ahead position. 3. Tilt the steering wheel in the downward position and lock the tilt handle. 4. Remove the driver air bag module. 5. Remove the steering wheel. 6. Remove the 2 screws and the instrument panel (I/P) lower steering column opening cover. 7. Remove the 3 screws and the lower steering column shroud. 8. Remove the upper steering column shroud. 9. Disconnect the clockspring electrical connector. 10. Remove the 2 screws and position aside the steering angle sensor. 11. Remove the 2 clockspring screws and remove the clockspring. Installation All vehicles 1. Install the clockspring and the 2 screws. 2. Position the steering angle sensor and install the 2 screws. 3. Connect the clockspring electrical connector. 4. Install the upper steering column shroud. 5. Install the lower steering column shroud and the 3 screws. 6. Install the I/P lower steering column opening cover and the 2 screws. Vehicles installing a new clockspring 7. Install the steering wheel. - After the steering wheel installation, remove the clockspring sealing key. Vehicle repairs reusing the same clockspring Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 7776 8. WARNING: Incorrect centralization may result in premature component failure. If in doubt when centralizing the clockspring, repeat the centralizing procedure. Failure to follow this instruction may result in personal injury. CAUTION: Make sure the road wheels are in the straight-ahead position. If the vehicle's clockspring has rotated out of center, follow these steps to center the clockspring. 1 Hold the clockspring outer housing stationary. 2 CAUTION: Overturning will destroy the clockspring. The internal ribbon wire acts as the stop and can be broken from its internal connection. While turning the rotor counterclockwise, carefully feel for the ribbon wire to run out of length and for a slight resistance. Stop turning at this point. 3 Turn the clockspring clockwise (approximately 2-1/2 turns) until the clockspring rotor wiring and connector are in the 12'o clock position. Clockspring is now centered. Do not allow the rotor to turn from this position. 9. CAUTION: If the vehicle is left unattended by the technician between centralizing the clockspring and installing the steering wheel, the centralizing procedure must be repeated. Install the steering wheel. All vehicles 10. Install the driver air bag module. 11. Repower the system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor, Left/Right View 151-1 (Engine Compartment - 4.0L, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor, Left/Right > Page 7781 View 151-15 (Left Rear, (1 0f 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor, Left/Right > Page 7782 View 151-17 (Right Rear, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor, Left/Right > Page 7783 View 151-21 (Driver Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor, Left/Right > Page 7784 View 151-22 (Passenger Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver Side Impact Sensor: Diagrams Side Impact Sensor, Driver Side C567A C567B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver Side > Page 7787 Impact Sensor: Diagrams Side Impact Sensor, Passenger Side C644A C644B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver Side > Page 7788 C1465 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver Side > Page 7789 C1466 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver Side > Page 7790 Impact Sensor: Diagrams C567A C567B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver Side > Page 7791 C644A C644B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver Side > Page 7792 C1465 C1466 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver Side > Page 7793 C3248 C3249 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Page 7794 Impact Sensor: Description and Operation SENSORS WARNING: - The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, a new RCM must be installed whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. - Vehicle sensor orientation is critical for correct restraint system operation. If a vehicle equipped with an SRS is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and correctly position the sensor or any other damaged SRS components whether or not the air bag is deployed. For these vehicles, the SRS uses up to 6 satellite sensors in addition to the RCM. The RCM is mounted to the center tunnel beneath the console. All vehicles will have 2 front impact severity sensors located in the front-center area of the vehicle, behind the grille mounted on the lower radiator support. The first row impact sensors are located in each of the front doors behind the trim panel. If the vehicle is equipped with safety canopies, there are 2 additional side impact sensors. The 2 additional sensors are located on each C-pillar. Mounting orientation and torque is critical for correct operation of all impact and rollover sensors. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor Impact Sensor: Service and Repair Front Impact Severity Sensor FRONT IMPACT SEVERITY SENSOR 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. - 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. Install and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To reduce the risk of personal injury, do not use any memory saver devices. 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. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 7797 - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. Depower the system. 2. Remove the 4 pin-type retainers and the lower radiator air deflector. 3. WARNING: The tightening torque of the air bag front impact severity sensor retaining nuts is critical for correct system operation. NOTE: Make sure the radiator support and front impact severity sensor mating surfaces are clean and free of foreign material. - Note position of locator tab on sensor bracket for installation. Remove the front impact severity sensor bolt. - To install, tighten to 12 Nm (9 lb-ft). 4. Disconnect the front impact severity sensor electrical connector and remove the sensor. 5. To install, reverse the removal procedure. 6. Repower the system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 7798 Impact Sensor: Service and Repair Side Impact Sensor C-Pillar SIDE IMPACT SENSOR - C-PILLAR Removal and 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. - Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air bag SRS is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Install a new sensor and correctly position the sensor or any other damaged SRS components whether or not the air bag is deployed. - To reduce the risk of personal injury, do not use any memory saver devices. 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 SRS fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 7799 - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - The LH and RH C-pillar mounted side impact sensors are not interchangeable. 1. Depower the system. 2. Remove the rear door scuff plate. 3. NOTE: Make sure the safety belt webbing is not twisted prior to installation. Remove the bolt and the safety belt anchor. To install, tighten to 40 Nm (30 lb-ft). 4. Detach the upper C-pillar trim panel and position aside. 5. Position aside the quarter trim panel. - Pull out on the quarter trim panel at the C-pillar to release the retaining clips and access the C-pillar side impact sensor. 6. Disconnect the side impact sensor electrical connector. 7. WARNING: The tightening torque of the air bag side impact sensor retaining bolts is critical for correct system operation. NOTE: Note the position of the sensor and bracket locating tab for installation. - Make sure the C-pillar and side impact severity sensor mating surfaces are clean and free of foreign material. Remove the 2 bolts and the side impact sensor and bracket assembly. To install, tighten to 12 Nm (9 lb-ft). 8. To install, reverse the removal procedure. 9. Repower the system. Front Door SIDE IMPACT SENSOR - FRONT DOOR Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 7800 Removal and 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. - Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air bag SRS is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Install a new sensor and correctly position the sensor or any other damaged SRS components whether or not the air bag is deployed. - To reduce the risk of personal injury, do not use any memory saver devices. 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 SRS fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - Driver side shown, passenger side similar. 1. Depower the system. 2. Remove the front interior door trim panel. 3. Detach the rearward lower corner of the watershield on the door to expose the side impact sensor. 4. Disconnect the side impact sensor electrical connector. 5. WARNING: The tightening torque of the side impact sensor retaining bolt is critical for correct system operation. CAUTION: The ground wire must be placed between the bolt head and the sensor. Never position the ground wire between the U-nut Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 7801 and the sensor. NOTE: Make sure the side impact sensor mating surfaces are clean and free of foreign material. - Note the position of the side impact sensor locating tabs for installation. Remove the bolt and the side impact sensor. To install, tighten to 9 Nm (80 lb-in). 6. To install, reverse the removal procedure. 7. Repower the system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Description and Operation Seat Occupant Classification Module - Air Bag: Description and Operation OCS SYSTEM MODULE Based on programmed limits, the OCS module will inform the RCM, via a High Speed Controller Area Network (HS-CAN), of the necessary information. The RCM uses this information in determining if the passenger air bag module or passenger seat side air bag module is to be deployed in the event of a deployable collision. The OCS module monitors the OCS system for faults and communicates on-demand and continuous diagnostic trouble codes (DTCs) via the DLC with the use of a scan tool. The components that make up the OCS system, OCS system module, inboard OCS rail and outboard OCS rail are serviced separately. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Description and Operation > Page 7805 Seat Occupant Classification Module - Air Bag: Service and Repair OCCUPANT CLASSIFICATION 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - Power seat shown, manual similar. - Seat is removed for clarity. 1. Depower the system. 2. From underneath the front of the seat, disconnect the OCS module electrical connector. 3. NOTE: Note the position of the locator tab on the OCS module for installation. Remove the 2 screws and the OCS module. To install, tighten to 2 Nm (18 lb-in). 4. To install, reverse the removal procedure. 5. Repower the SRS. Do not prove out the SRS at this time. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Description and Operation > Page 7806 6. Carry out the appropriate procedure after installation of an OCS system component. - If installing the original OCS system component, carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. See: Testing and Inspection/Component Tests and General Diagnostics/Occupant Classification Sensor (OCS) System Zero Seat Weight Test - If installing a new OCS system component, carry out the Occupant Classification Sensor (OCS) System Reset procedure and prove out the SRS. See: Service and Repair Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Locations > Occupant Classification Sensor (OCS) Module View 151-20 (Passenger Seat) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Locations > Occupant Classification Sensor (OCS) Module > Page 7811 View 151-20 (Passenger Seat) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Diagrams > Occupant Classification Sensor (OCS) Module C3159 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Diagrams > Occupant Classification Sensor (OCS) Module > Page 7814 C3291 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Diagrams > Occupant Classification Sensor (OCS) Module > Page 7815 C3292 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Description and Operation > OCS System Seat Occupant Sensor: Description and Operation OCS System OCS System The OCS system is found only on the front passenger seat. The front passenger OCS system is comprised of the following: 2 OCS rails (weight sensors) that are mounted to each side of the seat track; an OCS module (electronic control unit) which is mounted to the electrical bracket underneath the seat cushion pan. The weight of any occupant or object on the front passenger seat is electronically communicated to the OCS module. The OCS system is also used for operation of the passenger Belt Minder. To deactivate or reactivate the passenger Belt Minder feature, refer to Seat Belt Systems or the owner's literature. The components that make up the OCS system, OCS module, inboard OCS rail and outboard OCS rail are serviced separately. When the front passenger seat is removed for service, the Zero Seat Weight Test must be carried out after the installation of the front passenger seat. When a OCS system component is installed new, the System Reset must be carried out after the installation of the front passenger seat. The Zero Seat Weight Test and/or System Reset must be carried out only as instructed to do so. OCS Rails (Weight Sensors) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Description and Operation > OCS System > Page 7818 The components that make up the OCS system (OCS system module, inboard OCS rail and outboard OCS rail) are serviced separately. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Description and Operation > OCS System > Page 7819 Seat Occupant Sensor: Description and Operation Occupant Classification Sensor (OCS) System OCCUPANT CLASSIFICATION SENSOR (OCS) SYSTEM The occupant classification system (OCS) system is standard equipment on all front passenger seats. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Description and Operation > Page 7820 Seat Occupant Sensor: Service and Repair OCCUPANT CLASSIFICATION SENSOR Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Description and Operation > Page 7821 Part 2 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. - The occupant classification sensor rails have a built-in strain gauge which may operate incorrectly if an occupant classification sensor rail is dropped by itself, dropped when installed to the front passenger seat or dropped when installed to a front passenger seat track assembly. Use care when handling an occupant classification sensor rail or when installed to the front passenger seat of front passenger seat track assembly. Failure to follow these instructions may increase the risk of personal injury or death in a crash. - Do not disassemble the occupant classification sensor rail, tighten or loosen any of the nuts and bolts installed to the occupant classification sensor rail body. Only the 8 bolts that attach the 2 occupant classification sensor rails to the seat track should be removed and installed. Failure to follow these instructions may increase the risk of personal injury or death in a crash. - Oil, grease, water or foreign material on or in the occupant classification sensor rail may cause the supplemental restraint system to deploy incorrectly. Never allow oil, grease, water or foreign material to get on or into the occupant classification sensor rail. Failure to follow these instructions may increase the risk of personal injury or death in a crash. - To reduce the risk of personal injury, do not use any memory saver devices. 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: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - 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. - Outboard occupant classification sensor (OCS) rail shown, inboard similar. 1. Remove the passenger seat and depower the system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Description and Operation > Page 7822 2. CAUTION: Push only on the tip of the occupant classification sensor (OCS) electrical connector release tab to release the electrical connector. Do not insert the tool too deep into the OCS electrical connector or damage to the electrical connector may occur. NOTE: Note the position and the routing of the OCS rail electrical wiring, connector and wiring retainers for installation. On the affected side, detach the 2 OCS rail wiring retainers. Then using a suitable tool, release the tab and disconnect the OCS rail electrical connector. 3. If equipped, disconnect the power seat track motor electrical connector. 4. Move the seat to the forward most position. - If equipped with a power seat track, apply power and ground to the pins shown. 5. Remove the 2 rear bolts from the affected OCS rail. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Description and Operation > Page 7823 6. Move the seat to the rearward most position. - If equipped with a power seat track, apply power and ground to the pins shown. 7. NOTE: Note the position of where the locator tab on the OCS rail goes through the OCS rail shield and into the rear mounting point of the seat track for installation. Remove the 2 front bolts and the affected OCS rail and shield. Installation NOTE: If installing a new seat track, position the seat track where the seat will be in the rearward most position before starting installation of the OCS rails. 1. WARNING: The occupant classification sensor rail shield is an aid to prevent foreign material and contaminants from entering the occupant classification sensor rail. Make sure the occupant classification sensor rail shield is present, is not damaged and is correctly installed to the occupant classification sensor rail. Failure to follow these instructions may increase the risk of personal injury or death in a crash. NOTE: Make sure the OCS rail shield is seated correctly on the OCS rail. Align the locator tab to the shield. Position the OCS rail shield on the OCS rail. Then position the OCS rail and shield on the seat track while noting the correct installation of the OCS rail locator tab into the seat track. 2. NOTE: To make sure of correct installation, the OCS rail bolts must be installed in the sequence shown. While holding the OCS rail and shield firmly in position, install the OCS rail front mounting position rear bolt. Tighten to 25 Nm (18 lb-ft). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Description and Operation > Page 7824 3. While still holding the OCS rail and shield firmly in position, install the OCS rail front mounting position front bolt. - Tighten to 25 Nm (18 lb-ft). 4. Move the seat to the forward most position. - If equipped with a power seat track, apply power and ground to the pins shown. 5. Install the 2 rear OCS rail bolts. - Tighten to 25 Nm (18 lb-ft). 6. NOTE: Make sure to route the OCS rail wiring and install the 2 wiring retainers as noted during removal. Connect the OCS rail electrical connector. Then route the OCS rail wiring and attach the 2 wiring retainers. 7. Center the seat track to the seat cushion pan. - If equipped with a power seat track, apply power and ground to the pins shown. 8. If equipped, connect the power seat track motor electrical connector. 9. Install the passenger seat and repower the supplemental restraints system (SRS). Do not prove out the SRS at this time. 10. Carry out the appropriate procedure after installation of an OCS system component. - If installing the original OCS system component, carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. See: Testing and Inspection/Component Tests and General Diagnostics/Occupant Classification Sensor (OCS) System Zero Seat Weight Test - If installing a new OCS system component, carry out the Occupant Classification Sensor (OCS) System Reset procedure and prove out the SRS. See: Service and Repair Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Service and Repair Seat Position Sensor: Service and Repair SEAT POSITION SENSOR Removal and 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a SRS component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a SRS fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - Power seat track seat position sensor shown, manual seat track position sensor similar. 1. Position the front seat to the rearmost and upward position. 2. Depower the system. 3. Disconnect the seat position sensor electrical connector. 4. WARNING: The tightening torque of the seat position sensor retaining bolt is critical for correct system operation. NOTE: Note the position of the seat position sensor locating tab for installation. Remove the bolt and the seat position sensor. To install, tighten to 6 Nm (53 lb-in). 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Service and Repair > Page 7828 6. Repower the system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Description and Operation Side Air Bag: Description and Operation Driver Seat Side Air Bag Module NOTE: - References to seat side air bag modules refer to the seat-mounted and not to the steering wheel or instrument panel mounted air bag components of the SRS. - When servicing a seat equipped with a seat side air bag module, refer to Seats. A seat side air bag module provides protection of the thorax area (between the neck and abdomen) of the body, working in conjunction with the head protection provided by a safety canopy module (if equipped). The driver seat side air bag module: will deploy upon receiving a flow of current from the RCM initiated by the driver side impact sensor and internal RCM circuitry. - is installed as an assembly. - is mounted in the driver seat back. - is used in conjunction with a safety canopy module (if equipped). Passenger Seat Side Air Bag Module NOTE: - References to seat side air bag modules refer to the seat-mounted and not to the steering wheel or instrument panel mounted air bag components of the SRS. - When servicing a seat equipped with a seat side air bag module, refer to Seats. A seat side air bag module provides protection of the thorax area (between the neck and abdomen) of the body, working in conjunction with the head protection provided by a safety canopy module (if equipped). The passenger seat side air bag module: will deploy upon receiving a flow of current from the RCM initiated by the passenger side impact sensor and internal RCM circuitry. - is installed as an assembly. - is mounted in the passenger seat back. - is used in conjunction with a safety canopy module (if equipped). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Description and Operation > Page 7832 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 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 afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Side air bag modules with damaged covers must be installed new. - Front seat back trim covers installed on seats equipped with side air bags cannot be repaired, they are to be replaced. Cleaning is permissible. - To reduce the risk of personal injury, do not use any memory saver devices. 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 side air bag deployment took place, a new seat back pad, trim cover and side air bag module must be installed. The seat back frame should be replaced if necessary. - When replacing the side air bag after deployment, refer to Seats for additional information concerning the installation of a new side air bag. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Description and Operation > Page 7833 - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - Driver seat side air bag module shown, passenger side similar. 1. Remove the front seat and depower the system. 2. Remove the seat backrest. 3. NOTE: RH shown, LH similar. Remove the 2 plastic rivets attaching the backrest trim cover to the inboard and outboard recliners on the seat backrest frame. 4. Release the seat back lower outer trim cover J-clip. 5. Release the seat back lower inner trim cover J-clip. 6. WARNING: Front seat back trim covers installed on seats equipped with side air bags cannot be repaired; they are to be installed new (cleaning is permissible). 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. Place a hand between the seat backrest trim cover and foam pad and carefully separate the hook-and-loop strips, then carefully roll up the seat back trim cover in an inside out fashion to the first row of hog rings in the front. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Description and Operation > Page 7834 7. Remove the first row of hog rings. 8. Detach the hook-and-loop strips and invert the seat backrest trim cover up enough to expose the side air bag. 9. NOTE: Note the position and the routing of the side air bag module wiring harness for installation. Detach the side air bag wiring harness retainers from the seat backrest frame. 10. Position out the seat backrest foam pad. 11. Remove the 2 bolts and the side air bag module. Installation WARNING: - Inspect the mounting surfaces of the side air bag module and the seat back frame mounting bracket for any foreign material before installing the side air bag module. If any foreign material is found, remove it. 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 material. If the air bag module is damaged, install a new module. If any foreign material is found, remove it. Failure to do so may result in personal injury, in the event of an air bag deployment. - Inspect the side air bag cavity in the seat back pad for any foreign material. If any foreign material is found, remove it. 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: Make sure the side air bag module wiring harness is not pinched between the side air bag module and the backrest frame. All seats Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Description and Operation > Page 7835 1. Align the holes of the side air bag module bracket to the U-nuts on the backrest frame. - Install new U-nuts if installing a new side air bag module. 2. Slide the side air bag module onto the backrest frame so the bracket hook wraps around the backrest frame. 3. Install the side air bag module and the bolts. - Tighten to 10 Nm (89 lb-in). 4. Position back the seat backrest foam pad. 5. Attach the side air bag wiring harness retainers to the seat backrest frame. 6. Attach the hook-and-loop strips, and roll the seat back trim cover down and install the first row of hog rings. 7. Attach the hook-and-loop strips, and roll the seat back trim cover down and attach the seat back lower inner trim cover J-clip. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Description and Operation > Page 7836 8. Attach the seat back lower outer trim cover J-clip. 9. NOTE: RH shown, LH similar. Fold the backrest trim cover over on each side of the inboard and outboard recliner. Install the plastic rivets attaching the backrest trim cover to the inboard and outboard recliners on the seat backrest frame. 10. Install the seat backrest. 11. Install the passenger seat and repower the supplemental restraints system (SRS). Do not prove out the SRS at this time. Passenger seat 12. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. See: Testing and Inspection/Component Tests and General Diagnostics/Occupant Classification Sensor (OCS) System Zero Seat Weight Test Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs Air Bag Control Module: Technical Service Bulletins Restraints - Control Module DTCs & Associated Fault PIDs TSB 07-12-3 06/25/07 RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS) - SERVICE TIPS FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred, Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar 2005-2007 Escape Hybrid, Escape 2007 E-Series LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator 2003-2007 Navigator 2006-2007 Mark LT MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan 2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 07-7-8 to update the vehicle application. ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most 2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS) terminology and navigation which does not translate well when using Integrated Diagnostic System (IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS). ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool being used. SERVICE TIPS DTCs And Associated Fault PIDs Description Many of the continuous memory and on-demand DTCs that can be present in the RCM provide general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional DTCs. Conventional DTCs identify a specific concern for a given component and point to a particular diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7842 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7843 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7844 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7845 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7846 DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s) or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the specific device and fault condition. Fault PIDs are available for both on-demand (active) and continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures 1-5) VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools have transitioned. Examples of how the WSM may direct you to view fault PIDs are: ^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7847 ^ View and Record DTC XXXXX Fault PIDs (2007 WSM) ^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs) In each instance the direction is the same (view fault PIDs to identify the specific component and fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology, will vary. FLAG the DTC - View the Fault PIDs For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is necessary to view the fault PIDs from DataLogger. Using IDS/PDS NOTE WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS, HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION. 1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous memory DTCs. 2. To view the fault PIDs associated with an on-demand DTC: a. Toolbox b. DataLogger c. Modules d. RCM 3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". ^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads "FAULT' indicating a front internal crash sensor fault. 4. To view the fault PIDs associated with a continuous memory DTC: a. Toolbox b. DataLogger c. Modules d. RCM 5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads "FAULT" indicating a front internal crash sensor fault. IDS/PDS Fault PID Naming Conventions The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example, the fault PIDs 2296_18_OD and 2296_18_CM break down as follows: ^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation. ^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC. ^ OD - Identifies the fault PID as an on-demand fault. ^ CM - Identifies the fault PID as a continuous memory (intermittent) fault. NOTE THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON VEHICLE EQUIPMENT. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7848 Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5) WARRANTY STATUS: Information Only Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 7849 Air Bag Control Module: Locations View 151-12 (Center Console) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 7850 View 151-13 (Left Front) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 7851 Air Bag Control Module: Diagrams C310A Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 7852 C310B (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 7853 C310B (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 7854 Air Bag Control Module: Description and Operation RESTRAINTS CONTROL MODULE (RCM) WARNING: - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, a new RCM must be installed whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. CAUTION: When installing a new RCM on vehicles built 7/31/06 or after, it is necessary to carry out programmable module installation (PMI). NOTE: When installing a new RCM, always make sure the correct RCM is being installed. If an incorrect RCM is installed, erroneous DTCs will result. The RCM carries out the following functions: - deploys the air bag(s) in the event of a deployable crash. - activates the safety belt buckle pretensioner and safety belt adaptive load limiting retractor to control tension on the safety belt. - monitors the SRS for faults. - requests the illumination of the air bag indicator if a fault is detected. - communicates through the DLC the on-demand or continuous DTCs. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the ON position, the RCM will request illumination of 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 6 seconds and then off. If a SRS fault exists, the air bag indicator will illuminate and remain illuminated for the rest of the key cycle. The RCM will also communicate the on-demand (current) and continuous (historical) DTCs through the DLC, to the scan tool. If the RCM requests illumination of the air bag indicator and the air bag indicator does not function, the instrument cluster module will automatically activate an audible chime. The chime is a series of 5 sets of 5 tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. 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 lost or damaged during impact. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 7855 Air Bag Control Module: Service and Repair RESTRAINTS CONTROL MODULE (RCM) Special Tool(s) Special Tool(s) Removal WARNING: - Always wear safety glasses when repairing an air bag SRS vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - The RCM orientation is critical for correct air bag supplemental restraint system (SRS) operation. If a vehicle equipped with an SRS system has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the RCM must be installed new whether or not the air bags have deployed. In addition, make sure the area of Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 7856 the RCM mounting is restored to its original condition. - Vehicle sensor orientation is critical for correct 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. Install a new sensor and correctly position the sensor or any other damaged SRS components whether or not the air bag is deployed. - The tightening torque of the air bag RCM retaining nuts is critical for correct system operation. - To reduce the risk of personal injury, do not use any memory saver devices. CAUTION: - Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. - When installing a new RCM on vehicles built 7/31/06 or after, it is necessary to carry out programmable module installation (PMI). See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning NOTE: - When installing a new RCM, always make sure the correct RCM is being installed. If an incorrect RCM is installed, erroneous DTCs will result. - 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 SRS fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. Vehicles built 7/31/06 or after 1. Carry out the steps necessary to prepare for programmable module installation (PMI). All vehicles 2. Depower the system. 3. Remove the floor console. 4. Disconnect the large restraints control module (RCM) electrical connector. 1 Pinch the thumb tab and pivot the large RCM electrical connector position assurance lever all the way back until it stops. 2 Pull out and disconnect the large RCM electrical connector. 5. Press to release the locking tab and disconnect the small RCM electrical connector. 6. Remove the 3 RCM nuts. 7. Remove the RCM. Installation All vehicles 1. Install the RCM. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 7857 2. Install the 3 RCM nuts. - Tighten to 12 Nm (9 lb-ft). 3. Connect the small RCM electrical connector. 4. NOTE: The RCM has been removed for clarity. On the large RCM electrical connector, place the connector position assurance lever in the full release position. 5. CAUTION: Putting the large RCM electrical connector into the RCM on an angle can cause bad electrical connections and damage components. Position the large RCM electrical connector into the RCM. 6. Connect the large RCM connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 7858 - CAUTION: Do not push the connector on to where the lever pivots and seats itself. Light pressure is needed to get the connector into position on the RCM before using the lever to fully seat the connector. With the large RCM electrical connector uniformly aligned to the RCM, lightly push in until a subtle audible click is heard and a slight resistance is felt. - Using the connector position assurance lever, pivot it toward the RCM, drawing the connector into the RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place. 7. Install the floor console. 8. Repower the system. Do not prove out the SRS at this time. Vehicles built 7/31/06 or after 9. Carry out the steps necessary to complete PMI. All vehicles 10. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch 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 6 seconds and then turn off. If an air bag SRS fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag indicator might not light 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 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 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous diagnostic trouble codes (DTCs) from the RCM and occupant classification sensor (OCS) module using a scan tool. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs Seat Belt Control Module: Technical Service Bulletins Restraints - Control Module DTCs & Associated Fault PIDs TSB 07-12-3 06/25/07 RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS) - SERVICE TIPS FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred, Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar 2005-2007 Escape Hybrid, Escape 2007 E-Series LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator 2003-2007 Navigator 2006-2007 Mark LT MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan 2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 07-7-8 to update the vehicle application. ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most 2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS) terminology and navigation which does not translate well when using Integrated Diagnostic System (IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS). ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool being used. SERVICE TIPS DTCs And Associated Fault PIDs Description Many of the continuous memory and on-demand DTCs that can be present in the RCM provide general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional DTCs. Conventional DTCs identify a specific concern for a given component and point to a particular diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7863 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7864 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7865 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7866 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7867 DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s) or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the specific device and fault condition. Fault PIDs are available for both on-demand (active) and continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures 1-5) VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools have transitioned. Examples of how the WSM may direct you to view fault PIDs are: ^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7868 ^ View and Record DTC XXXXX Fault PIDs (2007 WSM) ^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs) In each instance the direction is the same (view fault PIDs to identify the specific component and fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology, will vary. FLAG the DTC - View the Fault PIDs For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is necessary to view the fault PIDs from DataLogger. Using IDS/PDS NOTE WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS, HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION. 1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous memory DTCs. 2. To view the fault PIDs associated with an on-demand DTC: a. Toolbox b. DataLogger c. Modules d. RCM 3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". ^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads "FAULT' indicating a front internal crash sensor fault. 4. To view the fault PIDs associated with a continuous memory DTC: a. Toolbox b. DataLogger c. Modules d. RCM 5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads "FAULT" indicating a front internal crash sensor fault. IDS/PDS Fault PID Naming Conventions The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example, the fault PIDs 2296_18_OD and 2296_18_CM break down as follows: ^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation. ^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC. ^ OD - Identifies the fault PID as an on-demand fault. ^ CM - Identifies the fault PID as a continuous memory (intermittent) fault. NOTE THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON VEHICLE EQUIPMENT. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7869 Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5) WARRANTY STATUS: Information Only Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Description and Operation Seat Occupant Classification Module - Air Bag: Description and Operation OCS SYSTEM MODULE Based on programmed limits, the OCS module will inform the RCM, via a High Speed Controller Area Network (HS-CAN), of the necessary information. The RCM uses this information in determining if the passenger air bag module or passenger seat side air bag module is to be deployed in the event of a deployable collision. The OCS module monitors the OCS system for faults and communicates on-demand and continuous diagnostic trouble codes (DTCs) via the DLC with the use of a scan tool. The components that make up the OCS system, OCS system module, inboard OCS rail and outboard OCS rail are serviced separately. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Description and Operation > Page 7873 Seat Occupant Classification Module - Air Bag: Service and Repair OCCUPANT CLASSIFICATION 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - Power seat shown, manual similar. - Seat is removed for clarity. 1. Depower the system. 2. From underneath the front of the seat, disconnect the OCS module electrical connector. 3. NOTE: Note the position of the locator tab on the OCS module for installation. Remove the 2 screws and the OCS module. To install, tighten to 2 Nm (18 lb-in). 4. To install, reverse the removal procedure. 5. Repower the SRS. Do not prove out the SRS at this time. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Description and Operation > Page 7874 6. Carry out the appropriate procedure after installation of an OCS system component. - If installing the original OCS system component, carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. See: Air Bag Systems/Testing and Inspection/Component Tests and General Diagnostics/Occupant Classification Sensor (OCS) System Zero Seat Weight Test - If installing a new OCS system component, carry out the Occupant Classification Sensor (OCS) System Reset procedure and prove out the SRS. See: Air Bag Systems/Service and Repair Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Depowering and Repowering SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING Special Tool(s) Special Tool(s) Depowering 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. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the electrical connector on a safety canopy module. Doing so can result in safety canopy deployment. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a SRS component is being serviced, the SRS must be depowered. - 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. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box (SJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse 17 (10A) from the SJB. 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 switch to OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or installing any front or side air bag supplemental restraint system (SRS) components and before servicing, installing, 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 front impact severity sensors are located on the radiator support bracket above the lower front splash shield. The front door side impact sensors are located in the first row doors, behind the door trim panel. The C-pillar side impact sensors (if equipped) are located on the C-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). Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7880 remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install RCM fuse 17 (10A) to the SJB and close the cover. 4. 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. 5. Prove out the SRS as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch 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 6 seconds and then turn off. If an air bag SRS fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag indicator might not light 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 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 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous diagnostic trouble codes (DTCs) from the RCM and occupant classification sensor (OCS) module using a scan tool. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7881 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Deactivation and Reactivation SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION Special Tool(s) Special Tool(s) Deactivation 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. - Never probe the connectors on the safety canopy module. Doing so can result in safety canopy deployment, which can result in personal injury. - The safety belt pretensioner and adaptive load limiting retractor are pyrotechnic devices. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner/adaptive load limiting retractor. Never probe a pretensioner or adaptive load limiting retractor electrical connector. Doing so could result in pretensioner, adaptive load limiting retractor or air bag deployment and could result in personal injury. - 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a SRS component is being serviced, the SRS must be depowered. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7882 - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a SRS fault. - 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 smart junction box (SJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse 17 (10A) from the SJB. 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 front impact severity sensors are located on the radiator support bracket above the lower front splash shield. The front door side impact sensors are located in the first row doors, behind the door trim panel. The C-pillar side impact sensors (if equipped) are located on the C-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). Disconnect the battery ground cable and wait at least one minute. 7. Remove the 2 driver air bag module bolts (1 shown). 8. NOTE: Note the position of the 3 driver air bag module wiring connectors for installation. Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag module. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7883 9. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of the steering column. 10. Open and lower the glove compartment door. 11. Detach the wiring retainer, remove the 4 bolts and the passenger air bag module heat shield. 12. NOTE: Deactivate the passenger air bag module as shown, the canister vent and adaptive tether squibs do not require deactivation. Through the glove compartment opening, disconnect the LH side passenger air bag module electrical connector. 13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector on the LH side. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7884 14. From under the rear of the passenger seat, detach the passenger seat side air bag module electrical connector from the seat track bracket. Then slide and disengage the passenger seat side air bag module electrical connector locking clip, and then release the tab and disconnect the passenger seat side air bag module electrical connector. 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat side air bag module electrical connector. Vehicles without safety canopy modules 16. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy bridge resistor from the safety canopy electrical connector. If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the RCM. If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low resistance fault will be generated by the RCM. Explorer and Mountaineer vehicles with safety canopy modules 17. Release and position aside the passenger side C-pillar trim panel. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7885 18. Disconnect the passenger side safety canopy module electrical connector. 19. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. 20. Release and position aside the driver side C-pillar trim panel. 21. Disconnect the driver side safety canopy module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7886 22. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. Explorer Sport Trac vehicles with safety canopy modules 23. Remove the driver and passenger side upper C-pillar trim panels. 24. Disconnect the passenger side safety canopy module electrical connector. 25. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. 26. Disconnect the driver side safety canopy module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7887 27. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. All vehicles 28. From under the rear of the driver seat, slide and disengage the driver seat side air bag module electrical connector locking clip, and then release the tab and disconnect the driver seat side air bag module electrical connector. 29. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air bag module electrical connector. 30. Install the RCM fuse 17 (10A) to the SJB. 31. Connect the battery ground cable. Reactivation All vehicles 1. Remove the RCM fuse 17 (10A) from the SJB. 2. Disconnect the battery ground cable and wait at least one minute. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7888 3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat side air bag module electrical connector. 4. Connect the driver seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Explorer Sport Trac vehicles with safety canopy modules 5. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 6. Connect the driver side safety canopy module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7889 7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 8. Connect the passenger side safety canopy module electrical connector. 9. Install the driver and passenger upper C-pillar trim panels. Explorer and Mountaineer vehicles with safety canopy modules 10. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 11. Connect the driver side safety canopy module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7890 12. Install the driver side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. 13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 14. Connect the passenger side safety canopy module electrical connector. 15. Install the passenger side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. All vehicles Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7891 16. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat side air bag module electrical connector. 17. Connect the passenger seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Then attach the passenger seat side air bag module electrical connector to the seat track bracket. 18. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector on the LH side. 19. Connect the LH side passenger air bag module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7892 20. Install the passenger air bag module heat shield and the 4 bolts. Attach the wiring retainer. 21. Close glove compartment door. 22. Remove the restraint system diagnostic tools from the clockspring electrical connectors at the top of the steering column. 23. CAUTION: The clockspring electrical connectors are unique and cannot be connected to the driver air bag module in the wrong position. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Connect the driver air bag module electrical connectors as noted in removal. 24. Install the 2 driver air bag module bolts (1 shown). - Tighten to 7 Nm (62 lb-in). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7893 25. 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. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 26. Turn the ignition switch from OFF to ON. 27. Install the RCM fuse 17 (10A) to the SJB and install the cover. 28. 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. 29. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the switch 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 6 seconds and then turn off. If an air bag SRS fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag indicator might not light 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 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 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and occupant classification sensor (OCS) module using a scan tool. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Child Safety Seat Tether Anchors WARNING: The child safety seat tether anchor/bolt MUST be securely tightened to specification. Otherwise, the child safety seat may not be correctly secured and the child could be injured if the vehicle is involved in a collision or stops suddenly. The second row outboard child safety seat tether anchors for a 5-passenger vehicle are located directly behind the seat, attached to the floor pan protruding from the carpet. Either of the tether anchors for a 5-passenger vehicle located near the back hatch door can be used for the second row center child safety seat tether anchor. There are also 2 child safety seat tether anchors/cargo tie downs located in the scuff plate at the back edge of the door. The 3 second row seats of a 7-passenger vehicle have child safety seat tether anchors that are located directly behind the second row seats attached to the floor pan, protruding from the carpet. The 2 third row child safety seat tether anchors are located directly behind the seat near the back hatch door. If the child safety seat tether anchors were in use during a collision, inspect and install new anchors as necessary. Return the vehicle structure to its original production configuration. Lower Anchors And Tethers For Children (LATCH) The lower anchors and tethers for children (LATCH) system is a standardized and uniform attachment system for installing child safety seats in passenger vehicles. LATCH-equipped child safety seats have 2 lower attachments that connect to the vehicle portion of the LATCH system. The vehicle portion of the system consists of 2 attachment points (6-mm wires) welded to the seat cushion frame. The attachment points protrude from the biteline between the seat cushion and seat backrest at the second row outboard seating positions. If a child safety seat was in use during a collision, inspect the vehicle portion of the system for damage. If any of the attachment points (6-mm wires) are damaged, install a new seat cushion frame. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > Child Safety Seat Tether Anchor - Second Row Child Seat Tether Attachment: Service and Repair Child Safety Seat Tether Anchor - Second Row CHILD SAFETY SEAT TETHER ANCHOR - SECOND ROW Removal and Installation WARNING: All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after any collision. All 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 new assemblies installed if either damage or incorrect operation is noted. Failure to follow these instructions could increase the risk of injury in collisions. NOTE: - Second row bucket seats shown, others similar. - Carpet removed for clarity. 1. Remove the bolt(s) and tether anchor(s). - To install, tighten to 40 Nm (30 lb-ft). 2. NOTE: Sealant must be applied to the tether anchor bolts when installed. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > Child Safety Seat Tether Anchor - Second Row > Page 7900 Child Seat Tether Attachment: Service and Repair Child Safety Seat Tether Anchor - Third Row CHILD SAFETY SEAT TETHER ANCHOR - THIRD ROW Removal and Installation WARNING: All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after any collision. All 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 new assemblies installed if either damage or incorrect operation is noted. Failure to follow these instructions could increase the risk of injury in collisions. 1. Remove the liftgate scuff plate trim panel. 2. Remove the tether anchor bolt(s) and tether anchor(s). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > Child Safety Seat Tether Anchor - Second Row > Page 7901 - To install, tighten to 40 Nm (30 lb-ft). 3. NOTE: Sealant must be applied to the tether anchor bolts when installed. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Description and Operation Seat Belt: Description and Operation SAFETY BELT EXTENSION ASSEMBLY 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. 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 the safety belt is too short for you when fully extended. Do not use an extension to change the fit of the shoulder belt across the torso. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Diagrams > Safety Belt Buckle Pretensioner, Driver C3201 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Diagrams > Safety Belt Buckle Pretensioner, Driver > Page 7909 C3202 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Diagrams > Page 7910 Seat Belt Buckle: Description and Operation SAFETY BELT BUCKLE AND PRETENSIONER The safety belt buckle and pretensioner is a pyrotechnic device that removes excess webbing from the safety belt when deployed. The pretensioner works in conjunction with the front air bag system. When the front air bags deploy, the pretensioners deploy, causing the buckle to move downward, removing excess webbing from the lap and shoulder safety belts. If the vehicle is involved in a collision that results in deployment of the front air bags and safety belt pretensioners, a new driver and passenger seat belt system (including safety belt buckle and pretensioners, safety belt retractors and height adjusters) must be installed. For safety belt buckle pretensioner diagnostic information, refer to Air Bag Systems. For safety belt buckle pretensioner disposal information, refer to Air Bag Systems. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, Bucket Seat Belt Buckle: Service and Repair Safety Belt Buckle - Second Row, Bucket SAFETY BELT BUCKLE - SECOND ROW, BUCKET Removal and Installation WARNING: All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after any collision. All 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 new assemblies installed if either damage or incorrect operation is noted. Failure to follow these instructions could increase the risk of injury in collisions. 1. Tilt the second row seat forward. 2. Remove the bolt and safety belt buckle. - To install, tighten to 47 Nm (35 lb-ft). 3. NOTE: Sealant must be applied to the safety belt buckle bolt when installed. To install, reverse the removal procedure. 4. Check the active restraint system for correct operation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, Bucket > Page 7913 Seat Belt Buckle: Service and Repair Safety Belt Buckle - Second Row, Center and RH, 60/40, Bench SAFETY BELT BUCKLE - SECOND ROW, CENTER AND RH, 60/40, BENCH Removal and Installation WARNING: All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after any collision. All 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 new assemblies installed if either damage or incorrect operation is noted. Failure to follow these instructions could increase the risk of injury in collisions. NOTE: Seat cushion removed for clarity. 1. Remove the 2 bolts and dual safety belt buckle. - To install, tighten to 40 Nm (30 lb-ft). 2. To install, reverse the removal procedure. 3. Check the active restraint system for correct operation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, Bucket > Page 7914 Seat Belt Buckle: Service and Repair Safety Belt Buckle - Second Row, Center and RH, 60/40, E-Z Entry SECOND ROW, CENTER AND RH, 60/40, E-Z ENTRY Removal and Installation WARNING: All safety belt assemblies (including retractors, buckles, belt tension sensors [BTS] if equipped, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after any collision. All 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 new assemblies installed if either damage or incorrect operation is noted. Failure to follow these instructions could increase the risk of injury in collisions. NOTE: Seat is removed from the vehicle for clarity. 1. Remove the 2 bolts and dual safety belt buckle assembly. - To install, tighten to 40 Nm (30 lb-ft). 2. To install, reverse the removal procedure. 3. Check the active restraint system for correct operation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, Bucket > Page 7915 Seat Belt Buckle: Service and Repair Safety Belt Buckle - Second Row, LH, 60/40, Bench SAFETY BELT BUCKLE - SECOND ROW, LH, 60/40, BENCH Removal and Installation WARNING: All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after any collision. All 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 new assemblies installed if either damage or incorrect operation is noted. Failure to follow these instructions could increase the risk of injury in collisions. 1. Remove the 40 percent seat from the vehicle. 2. Remove the bolt and safety belt buckle. - To install, tighten to 55 Nm (41 lb-ft). 3. To install, reverse the removal procedure. 4. Check the active restraint system for correct operation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, Bucket > Page 7916 Seat Belt Buckle: Service and Repair Safety Belt Buckle - Second Row, Bucket SAFETY BELT BUCKLE - SECOND ROW, BUCKET Removal and Installation WARNING: All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after any collision. All 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 new assemblies installed if either damage or incorrect operation is noted. Failure to follow these instructions could increase the risk of injury in collisions. 1. Tilt the second row seat forward. 2. Remove the bolt and safety belt buckle. - To install, tighten to 47 Nm (35 lb-ft). 3. NOTE: Sealant must be applied to the safety belt buckle bolt when installed. To install, reverse the removal procedure. 4. Check the active restraint system for correct operation. Safety Belt Buckle - Second Row, Center and RH, 60/40, Bench SAFETY BELT BUCKLE - SECOND ROW, CENTER AND RH, 60/40, BENCH Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, Bucket > Page 7917 Removal and Installation WARNING: All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after any collision. All 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 new assemblies installed if either damage or incorrect operation is noted. Failure to follow these instructions could increase the risk of injury in collisions. NOTE: Seat cushion removed for clarity. 1. Remove the 2 bolts and dual safety belt buckle. - To install, tighten to 40 Nm (30 lb-ft). 2. To install, reverse the removal procedure. 3. Check the active restraint system for correct operation. Safety Belt Buckle - Second Row, Center and RH, 60/40, E-Z Entry SECOND ROW, CENTER AND RH, 60/40, E-Z ENTRY Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, Bucket > Page 7918 Removal and Installation WARNING: All safety belt assemblies (including retractors, buckles, belt tension sensors [BTS] if equipped, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after any collision. All 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 new assemblies installed if either damage or incorrect operation is noted. Failure to follow these instructions could increase the risk of injury in collisions. NOTE: Seat is removed from the vehicle for clarity. 1. Remove the 2 bolts and dual safety belt buckle assembly. - To install, tighten to 40 Nm (30 lb-ft). 2. To install, reverse the removal procedure. 3. Check the active restraint system for correct operation. Safety Belt Buckle - Second Row, LH, 60/40, Bench SAFETY BELT BUCKLE - SECOND ROW, LH, 60/40, BENCH Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, Bucket > Page 7919 Removal and Installation WARNING: All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after any collision. All 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 new assemblies installed if either damage or incorrect operation is noted. Failure to follow these instructions could increase the risk of injury in collisions. 1. Remove the 40 percent seat from the vehicle. 2. Remove the bolt and safety belt buckle. - To install, tighten to 55 Nm (41 lb-ft). 3. To install, reverse the removal procedure. 4. Check the active restraint system for correct operation. Safety Belt Buckle - Second Row, LH, 60/40, E-Z Entry SAFETY BELT BUCKLE - SECOND ROW, LH, 60/40, E-Z ENTRY Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, Bucket > Page 7920 Removal and Installation WARNING: All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after any collision. All 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 new assemblies installed if either damage or incorrect operation is noted. Failure to follow these instructions could increase the risk of injury in collisions. 1. Tilt the seat forward. 2. Remove the 2 screws and inboard side shield. 3. Remove the bolt and safety belt buckle. - To install, tighten to 55 Nm (41 lb-ft). 4. To install, reverse the removal procedure. 5. Check the active restraint system for correct operation. Safety Belt Buckle - Third Row SAFETY BELT BUCKLE - THIRD ROW Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, Bucket > Page 7921 Removal and Installation WARNING: All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after any collision. All 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 new assemblies installed if either damage or incorrect operation is noted. Failure to follow these instructions could increase the risk of injury in collisions. NOTE: Power seat shown, manual similar. 1. Remove the RH third row seat. 2. Remove the nut and dual safety belt buckle assembly. - To install, tighten to 75 Nm (55 lb-ft). 3. To install, reverse the removal procedure. 4. Check the active restraint system for correct operation. Safety Belt Buckle and Pretensioner SAFETY BELT BUCKLE AND PRETENSIONER Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, Bucket > Page 7922 Removal and Installation WARNING: - All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after any collision. All 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 new assemblies installed if either damage or incorrect operation is noted. Failure to follow these instructions could increase the risk of injury in collisions. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the restraint control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a SRS fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - LH shown, RH similar. All seats NOTE: If equipped with power seats, position the passenger seat track downward to access the safety belt retractor anchor bolt. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, Bucket > Page 7923 1. Position the seat so it does not engage the safety belt buckle and pretensioner bracket and allows access to all 4 seat-to-floor fasteners. 2. Remove the affected seat and depower the SRS. 3. Remove the safety belt buckle pretensioner electrical connector cover. 4. Disconnect the safety belt buckle electrical connectors. 5. Remove the 2 nuts and safety belt buckle pretensioner. - To install, tighten to 36 Nm (27 lb-ft). 6. To install, reverse the removal procedure. 7. Install the affected seat and repower the SRS. If the passenger seat has been serviced, do not prove out the SRS at this time. Passenger seat 8. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. See: Air Bag Systems/Testing and Inspection/Component Tests and General Diagnostics/Occupant Classification Sensor (OCS) System Zero Seat Weight Test All seats 9. Check the active restraint system for correct operation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger View 151-20 (Passenger Seat) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger > Page 7928 View 151-19 (Driver Seat) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver C3065 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver > Page 7931 C3066 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Page 7932 Seat Belt Buckle Switch: Description and Operation SAFETY BELT BUCKLE SWITCHES As part of the SRS, the front safety belt buckles are equipped with safety belt buckle switches. The safety belt buckle switches are comprised of integrated circuits called Hall-effect sensors. The safety belt buckle switches (Hall-effect sensors) are located in the driver and front passenger safety belt buckles. The safety belt buckle switches indicate to the RCM whether the safety belts are buckled or unbuckled. The RCM uses this information in determining the deployment rate of the dual-stage driver and passenger air bag modules. The RCM also communicates the driver safety belt buckle switch status to the instrument cluster module, which monitors the information to control the safety belt warning indicator. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs Seat Belt Control Module: Technical Service Bulletins Restraints - Control Module DTCs & Associated Fault PIDs TSB 07-12-3 06/25/07 RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS) - SERVICE TIPS FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred, Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar 2005-2007 Escape Hybrid, Escape 2007 E-Series LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator 2003-2007 Navigator 2006-2007 Mark LT MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan 2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 07-7-8 to update the vehicle application. ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most 2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS) terminology and navigation which does not translate well when using Integrated Diagnostic System (IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS). ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool being used. SERVICE TIPS DTCs And Associated Fault PIDs Description Many of the continuous memory and on-demand DTCs that can be present in the RCM provide general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional DTCs. Conventional DTCs identify a specific concern for a given component and point to a particular diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7937 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7938 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7939 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7940 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7941 DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s) or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the specific device and fault condition. Fault PIDs are available for both on-demand (active) and continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures 1-5) VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools have transitioned. Examples of how the WSM may direct you to view fault PIDs are: ^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7942 ^ View and Record DTC XXXXX Fault PIDs (2007 WSM) ^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs) In each instance the direction is the same (view fault PIDs to identify the specific component and fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology, will vary. FLAG the DTC - View the Fault PIDs For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is necessary to view the fault PIDs from DataLogger. Using IDS/PDS NOTE WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS, HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION. 1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous memory DTCs. 2. To view the fault PIDs associated with an on-demand DTC: a. Toolbox b. DataLogger c. Modules d. RCM 3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". ^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads "FAULT' indicating a front internal crash sensor fault. 4. To view the fault PIDs associated with a continuous memory DTC: a. Toolbox b. DataLogger c. Modules d. RCM 5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads "FAULT" indicating a front internal crash sensor fault. IDS/PDS Fault PID Naming Conventions The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example, the fault PIDs 2296_18_OD and 2296_18_CM break down as follows: ^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation. ^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC. ^ OD - Identifies the fault PID as an on-demand fault. ^ CM - Identifies the fault PID as a continuous memory (intermittent) fault. NOTE THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON VEHICLE EQUIPMENT. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7943 Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5) WARRANTY STATUS: Information Only Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair Seat Belt Height Adjuster: Service and Repair SAFETY BELT SHOULDER HEIGHT ADJUSTER Removal and Installation WARNING: All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after any collision. All 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 new assemblies installed if either damage or incorrect operation is noted. Failure to follow these instructions could increase the risk of injury in collisions. 1. NOTE: Inspect the D-ring cover for damage. If the cover is damage or does not remain attached, install a new D-ring cover. Remove the D-ring cover. 2. Remove the bolt and D-ring. - To install, tighten to 48 Nm (35 lb-ft). 3. Remove the upper B-pillar trim panel. 4. Lower the shoulder safety belt height adjuster to the most downward position. 5. Remove the bolt. - To install, tighten to 40 Nm (30 lb-ft). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Page 7947 6. Remove the safety belt shoulder height adjuster. 1 Rotate the safety belt shoulder height adjuster downward to release the lower tab. 2 Remove the safety belt shoulder height adjuster. 7. To install, reverse the removal procedure. 8. Check the active restraint system for correct operation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation Safety Belt Warning Indicator And Chime The warning indicator and chime are reminders to fasten the safety belt. The system operates as follows: If the driver safety belt is not buckled before the ignition switch is turned to the RUN or START position, the indicator will illuminate for 1-2 minutes and the chime will sound for 4-8 seconds. - If the driver safety belt is buckled while the indicator is on and the chime is sounding, both the indicator and chime will turn off. - If the safety belt is buckled before the ignition is turned to the ON position, neither the indicator nor the chime will turn on. Belt Minder The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature provides an additional reminder that the driver's and/or front passenger's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning lamp in the instrument cluster. To activate or deactivate the Belt Minder feature, refer to Seat Belt Systems or the owner's literature. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Description and Operation > Safety Belt Systems Seat Belt Retractor: Description and Operation Safety Belt Systems Safety Belt Adaptive Load Limiting Retractor This vehicle is equipped with a driver and front passenger adaptive load limiting retractors. Adaptive load limiting retractors are pyrotechnic devices integrated to the driver and front passenger safety belt retractor assemblies. Adaptive load limiting retractors work in conjunction with the safety belt buckle pretensioners to control the tension of the driver and front passenger safety belts. The RCM monitors the readiness of the adaptive load limiting retractor. The RCM uses this information and all other information provided by the restraints system to determine what action to be taken. Dual Locking Mode Retractors WARNING: After any vehicle collision, the safety belt system at all outboard seating positions (except driver, which has no automatic locking retractor [ALR] feature) must be checked by a qualified technician to verify that the ALR feature for child seats is still functioning correctly, in addition to other checks for correct safety belt system function. A new belt and retractor assembly must be installed if the safety belt assembly's ALR feature or any other safety belt function is not operating correctly when checked according to the procedures. Failure to install a new belt and retractor assembly could increase the risk of injury in collisions. NOTE: When installing 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, 3-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 safety 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. The automatic locking mode must be used when installing a child safety seat in the front or rear passenger seating positions where dual locking mode retractors are provided. Energy Management Retractor 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. The energy management retractor feature is designed to pay out webbing in a controlled manner. This feature is designed to help reduce the belt force acting on an occupant's chest. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Description and Operation > Safety Belt Systems > Page 7955 Seat Belt Retractor: Description and Operation Supplemental Restraint System ADAPTIVE LOAD LIMITING SAFETY BELT RETRACTOR This vehicle is equipped with driver and passenger adaptive load limiting retractors. Adaptive load limiting retractors are pyrotechnic devices integrated to the driver and passenger safety belt retractor assemblies. Adaptive load limiting retractors work in conjunction with the safety belt buckle pretensioners and control the tension of the driver and passenger seat belts in the event of a deployable collision. The RCM monitors the readiness of the adaptive load limiting retractors. The RCM uses this information and all other information provided by the restraints system to determine what action is to be taken. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front Seat Belt Retractor: Service and Repair Safety Belt Retractor - Front SAFETY BELT RETRACTOR - FRONT Removal and Installation WARNING: - All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after any collision. All 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 new assemblies installed if either damage or incorrect operation is noted. The automatic locking retractor (ALR) feature of the safety belt retractor must be checked by a qualified technician to verify that the ALR feature for a child safety seat is functioning correctly, in addition to other checks for correct safety belt system function. A new belt Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 7958 and retractor assembly must be installed if the safety belt assembly's ALR feature or any other safety belt function is not operating correctly when inspected according to the functional inspection procedures. Failure to install a new belt and retractor assembly could increase the risk of injury in collisions. - The safety belt retractor is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the restraint control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - LH shown, RH similar. 1. If equipped with power seats, position the passenger seat track downward to access the safety belt retractor anchor bolt. 2. Depower the SRS. 3. Remove the safety belt anchor cover from the side of the seat. 4. Remove the bolt and safety belt anchor. - To install, tighten to 40 Nm (30 lb-ft). 5. NOTE: If the D-ring cover is damaged or does not remain attached, install a new D-ring cover. Remove the D-ring cover. 6. Remove the bolt and D-ring. - To install, tighten to 48 Nm (35 lb-ft). 7. Remove the upper and lower B-pillar trim panels. 8. Remove the secondary safety belt guide. 9. Disconnect the electrical connector. 10. Remove the bolt and safety belt retractor. - To install, tighten to 40 Nm (30 lb-ft). 11. To install, reverse the removal procedure. 12. Repower the SRS. 13. Check the active restraint system for correct operation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 7959 Seat Belt Retractor: Service and Repair Safety Belt Retractor - Second Row, Center, 60/40, Bench SAFETY BELT RETRACTOR - SECOND ROW, CENTER, 60/40, BENCH Removal and Installation WARNING: All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after any collision. All 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 new assemblies installed if either damage or incorrect operation is noted. The automatic locking retractor (ALR) feature of the safety belt retractor must be checked by a qualified technician to verify that the ALR feature for a child safety seat is functioning correctly, in addition to other checks for correct safety belt system function. A new belt and retractor assembly must be installed if the safety belt assembly's ALR feature or any other safety belt function is not operating correctly when inspected according to the functional inspection procedures. Failure to install a new belt and retractor assembly could increase the risk of injury in collisions. 1. Remove the second row, 40 percent seat. 2. Remove the bolt and safety belt anchor. - To install, tighten to 75 Nm (55 lb-ft). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 7960 3. NOTE: LH shown, RH similar. Remove the 4 screws and position aside the latch covers. 4. Remove the safety belt guide cover. 5. Release the J-clip at the bottom of the seat backrest. 6. Remove all the staples in the backrest support panel. 7. CAUTION: Use care when separating the seat upholstery from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat backrest foam pad. Separate the hook-and-loop fasteners. Invert the seat backrest trim cover and position aside. 8. Position aside the backrest foam pad. 9. Remove the safety belt retractor cover. 10. Remove the bolt and safety belt retractor. - To install, tighten to 75 Nm (55 lb-ft). 11. To install, reverse the removal procedure. 12. Check the active restraint system for correct operation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 7961 Seat Belt Retractor: Service and Repair Safety Belt Retractor - Second Row, Center, 60/40, E-Z Entry SAFETY BELT RETRACTOR - SECOND ROW, CENTER, 60/40, E-Z ENTRY Removal and Installation WARNING: All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after any collision. All 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 new assemblies installed if either damage or incorrect operation is noted. The automatic locking retractor (ALR) feature of the safety belt retractor must be checked by a qualified technician to verify that the ALR feature for a child safety seat is functioning correctly, in addition to other checks for correct safety belt system function. A new belt and Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 7962 retractor assembly must be installed if the safety belt assembly's ALR feature or any other safety belt function is not operating correctly when inspected according to the functional inspection procedures. Failure to install a new belt and retractor assembly could increase the risk of injury in collisions. NOTE: Seat is removed and exploded for clarity. 1. Fold the seat and tilt to the E-Z entry position. 2. Remove the 3 screws and inboard recliner outer cover side shield. 3. Remove the bolt and safety belt anchor. - To install, tighten to 55 Nm (41 lb-ft). 4. Release the backrest trim cover retainers. 5. Remove the safety belt bezel. 6. NOTE: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Invert the backrest trim cover. 7. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Release the hook-and-loop strips. 8. Remove the pin-type retainer and safety belt retractor cover and insulator. 9. Remove the bolt and safety belt retractor. - To install, tighten to 75 Nm (55 lb-ft). 10. To install, reverse the removal procedure. 11. Check the active restraint system for correct operation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 7963 Seat Belt Retractor: Service and Repair Safety Belt Retractor - Second Row, Outboard SAFETY BELT RETRACTOR - SECOND ROW, OUTBOARD Explorer/Mountaineer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 7964 Explorer Sport Trac Removal and Installation WARNING: All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after any collision. All 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 new assemblies installed if either damage or incorrect operation is noted. The automatic locking retractor (ALR) feature of the safety belt retractor must be checked by a qualified technician to verify that the ALR feature for a child safety seat is functioning correctly, in addition to other checks for correct safety belt system function. A new belt and retractor assembly must be installed if the safety belt assembly's ALR feature or any other safety belt function is not operating correctly when inspected according to the functional inspection procedures. Failure to install a new belt and retractor assembly could increase the risk of injury in collisions. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 7965 Explorer/Mountaineer and Explorer Sport Trac with 60/40 bench seat 1. Remove the appropriate 60 percent or 40 percent bench seat. Explorer Sport Trac 2. Remove the rear trim panels. Explorer/Mountaineer with 60/40 E-Z entry seat 3. Tilt the headrest to the E-Z entry position. 4. Fold the appropriate seat and tilt FORWARD to the E-Z entry position. Explorer/Mountaineer with 60/40 E-Z entry and bench seat 5. Remove the upper C-trim pillar panel. 6. Position the rear quarter trim panel aside to access the safety belt retractor. All vehicles 7. Remove the bolt and safety belt retractor anchor. - To install, tighten to 40 Nm (30 lb-ft). 8. Remove the bolt and D-ring. - To install, tighten to 40 Nm (30 lb-ft). 9. Remove the bolt and safety belt retractor. - To install, tighten to 40 Nm (30 lb-ft). 10. To install, reverse the removal procedure. 11. Check the active restraint system for correct operation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 7966 Seat Belt Retractor: Service and Repair Safety Belt Retractor - Third Row SAFETY BELT RETRACTOR - THIRD ROW Removal and Installation WARNING: All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after any collision. All 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 new assemblies installed if either damage or incorrect operation is noted. The automatic locking retractor (ALR) feature of the safety belt retractor must be checked by a qualified technician to verify that the ALR feature for a child safety seat is functioning correctly, in addition to other checks for correct safety belt system function. A new belt and retractor assembly must be installed if the safety belt assembly's ALR feature or any other safety belt function is not operating correctly when Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 7967 inspected according to the functional inspection procedures. Failure to install a new belt and retractor assembly could increase the risk of injury in collisions. 1. Remove the rear quarter trim panel. 2. Remove the bolt and D-ring. - To install, tighten to 40 Nm (30 lb-ft). 3. Remove the bolt and safety belt retractor anchor. - To install, tighten to 40 Nm (30 lb-ft). 4. Remove the bolt and safety belt retractor. - To install, tighten to 40 Nm (30 lb-ft). 5. To install, reverse the removal procedure. 6. Check the active restraint system for correct operation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Driver Safety Belt Retractor Pretensioner C323 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Driver Safety Belt Retractor Pretensioner > Page 7972 C303 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Driver Safety Belt Retractor Pretensioner > Page 7973 C3201 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Driver Safety Belt Retractor Pretensioner > Page 7974 C3202 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Attaching Safety Seats With Tether Straps Seat Belt Tensioner: Description and Operation Attaching Safety Seats With Tether Straps 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. Refer to Child Safety Seat Tether Anchor - Second Row and Child Safety Seat Tether Anchor Third Row in the removal and installation portion or the owner's literature for usage information. See: Child Restraint/Child Seat Tether Attachment/Service and Repair/Child Safety Seat Tether Anchor - Second Row See: Child Restraint/Child Seat Tether Attachment/Service and Repair/Child Safety Seat Tether Anchor - Third Row Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Attaching Safety Seats With Tether Straps > Page 7977 Seat Belt Tensioner: Description and Operation Safety Belt Buckle Pretensioners SAFETY BELT BUCKLE PRETENSIONERS As part of the SRS, the safety belt buckles are equipped with pretensioners. The safety belt buckle pretensioners remove excess slack from the safety belt webbing. The pretensioners are activated by the RCM when the module detects a crash event force exceeding a programmed limit. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Page 7978 Seat Belt Tensioner: Service and Repair SAFETY BELT BUCKLE AND PRETENSIONER Removal and Installation WARNING: - All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped, buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching hardware) should be inspected after any collision. All 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 new assemblies installed if either damage or incorrect operation is noted. Failure to follow these instructions could increase the risk of injury in collisions. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the restraint control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a SRS fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - LH shown, RH similar. All seats Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Page 7979 NOTE: If equipped with power seats, position the passenger seat track downward to access the safety belt retractor anchor bolt. 1. Position the seat so it does not engage the safety belt buckle and pretensioner bracket and allows access to all 4 seat-to-floor fasteners. 2. Remove the affected seat and depower the SRS. 3. Remove the safety belt buckle pretensioner electrical connector cover. 4. Disconnect the safety belt buckle electrical connectors. 5. Remove the 2 nuts and safety belt buckle pretensioner. - To install, tighten to 36 Nm (27 lb-ft). 6. To install, reverse the removal procedure. 7. Install the affected seat and repower the SRS. If the passenger seat has been serviced, do not prove out the SRS at this time. Passenger seat 8. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. See: Air Bag Systems/Testing and Inspection/Component Tests and General Diagnostics/Occupant Classification Sensor (OCS) System Zero Seat Weight Test All seats 9. Check the active restraint system for correct operation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tower Position Sensor > Component Information > Description and Operation Seat Belt Tower Position Sensor: Description and Operation SEAT TRACK POSITION SENSOR The seat track position sensor is a Hall-effect sensor located on the driver seat track. The seat track position sensor informs the RCM of the driver seat position. Based on programmed limits, the seat track position sensor will inform the RCM of the driver seat position. The RCM uses this information in determining the deployment rate of the dual-stage driver air bag module. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations View 151-19 (Driver Seat) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Page 7986 C356 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor, Left/Right View 151-1 (Engine Compartment - 4.0L, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor, Left/Right > Page 7992 View 151-15 (Left Rear, (1 0f 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor, Left/Right > Page 7993 View 151-17 (Right Rear, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor, Left/Right > Page 7994 View 151-21 (Driver Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Forward Crash Sensor, Left/Right > Page 7995 View 151-22 (Passenger Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver Side Impact Sensor: Diagrams Side Impact Sensor, Driver Side C567A C567B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver Side > Page 7998 Impact Sensor: Diagrams Side Impact Sensor, Passenger Side C644A C644B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver Side > Page 7999 C1465 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver Side > Page 8000 C1466 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver Side > Page 8001 Impact Sensor: Diagrams C567A C567B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver Side > Page 8002 C644A C644B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver Side > Page 8003 C1465 C1466 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, Driver Side > Page 8004 C3248 C3249 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Page 8005 Impact Sensor: Description and Operation SENSORS WARNING: - The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, a new RCM must be installed whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. - Vehicle sensor orientation is critical for correct restraint system operation. If a vehicle equipped with an SRS is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and correctly position the sensor or any other damaged SRS components whether or not the air bag is deployed. For these vehicles, the SRS uses up to 6 satellite sensors in addition to the RCM. The RCM is mounted to the center tunnel beneath the console. All vehicles will have 2 front impact severity sensors located in the front-center area of the vehicle, behind the grille mounted on the lower radiator support. The first row impact sensors are located in each of the front doors behind the trim panel. If the vehicle is equipped with safety canopies, there are 2 additional side impact sensors. The 2 additional sensors are located on each C-pillar. Mounting orientation and torque is critical for correct operation of all impact and rollover sensors. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor Impact Sensor: Service and Repair Front Impact Severity Sensor FRONT IMPACT SEVERITY SENSOR 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. - 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. Install and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To reduce the risk of personal injury, do not use any memory saver devices. 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. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 8008 - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. Depower the system. 2. Remove the 4 pin-type retainers and the lower radiator air deflector. 3. WARNING: The tightening torque of the air bag front impact severity sensor retaining nuts is critical for correct system operation. NOTE: Make sure the radiator support and front impact severity sensor mating surfaces are clean and free of foreign material. - Note position of locator tab on sensor bracket for installation. Remove the front impact severity sensor bolt. - To install, tighten to 12 Nm (9 lb-ft). 4. Disconnect the front impact severity sensor electrical connector and remove the sensor. 5. To install, reverse the removal procedure. 6. Repower the system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 8009 Impact Sensor: Service and Repair Side Impact Sensor C-Pillar SIDE IMPACT SENSOR - C-PILLAR Removal and 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. - Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air bag SRS is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Install a new sensor and correctly position the sensor or any other damaged SRS components whether or not the air bag is deployed. - To reduce the risk of personal injury, do not use any memory saver devices. 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 SRS fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 8010 - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - The LH and RH C-pillar mounted side impact sensors are not interchangeable. 1. Depower the system. 2. Remove the rear door scuff plate. 3. NOTE: Make sure the safety belt webbing is not twisted prior to installation. Remove the bolt and the safety belt anchor. To install, tighten to 40 Nm (30 lb-ft). 4. Detach the upper C-pillar trim panel and position aside. 5. Position aside the quarter trim panel. - Pull out on the quarter trim panel at the C-pillar to release the retaining clips and access the C-pillar side impact sensor. 6. Disconnect the side impact sensor electrical connector. 7. WARNING: The tightening torque of the air bag side impact sensor retaining bolts is critical for correct system operation. NOTE: Note the position of the sensor and bracket locating tab for installation. - Make sure the C-pillar and side impact severity sensor mating surfaces are clean and free of foreign material. Remove the 2 bolts and the side impact sensor and bracket assembly. To install, tighten to 12 Nm (9 lb-ft). 8. To install, reverse the removal procedure. 9. Repower the system. Front Door SIDE IMPACT SENSOR - FRONT DOOR Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 8011 Removal and 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. - Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air bag SRS is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Install a new sensor and correctly position the sensor or any other damaged SRS components whether or not the air bag is deployed. - To reduce the risk of personal injury, do not use any memory saver devices. 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 SRS fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - Driver side shown, passenger side similar. 1. Depower the system. 2. Remove the front interior door trim panel. 3. Detach the rearward lower corner of the watershield on the door to expose the side impact sensor. 4. Disconnect the side impact sensor electrical connector. 5. WARNING: The tightening torque of the side impact sensor retaining bolt is critical for correct system operation. CAUTION: The ground wire must be placed between the bolt head and the sensor. Never position the ground wire between the U-nut Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 8012 and the sensor. NOTE: Make sure the side impact sensor mating surfaces are clean and free of foreign material. - Note the position of the side impact sensor locating tabs for installation. Remove the bolt and the side impact sensor. To install, tighten to 9 Nm (80 lb-in). 6. To install, reverse the removal procedure. 7. Repower the system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger View 151-20 (Passenger Seat) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger > Page 8017 View 151-19 (Driver Seat) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver C3065 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver > Page 8020 C3066 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Page 8021 Seat Belt Buckle Switch: Description and Operation SAFETY BELT BUCKLE SWITCHES As part of the SRS, the front safety belt buckles are equipped with safety belt buckle switches. The safety belt buckle switches are comprised of integrated circuits called Hall-effect sensors. The safety belt buckle switches (Hall-effect sensors) are located in the driver and front passenger safety belt buckles. The safety belt buckle switches indicate to the RCM whether the safety belts are buckled or unbuckled. The RCM uses this information in determining the deployment rate of the dual-stage driver and passenger air bag modules. The RCM also communicates the driver safety belt buckle switch status to the instrument cluster module, which monitors the information to control the safety belt warning indicator. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Tower Position Sensor > Component Information > Description and Operation Seat Belt Tower Position Sensor: Description and Operation SEAT TRACK POSITION SENSOR The seat track position sensor is a Hall-effect sensor located on the driver seat track. The seat track position sensor informs the RCM of the driver seat position. Based on programmed limits, the seat track position sensor will inform the RCM of the driver seat position. The RCM uses this information in determining the deployment rate of the dual-stage driver air bag module. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Locations > Occupant Classification Sensor (OCS) Module View 151-20 (Passenger Seat) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Locations > Occupant Classification Sensor (OCS) Module > Page 8029 View 151-20 (Passenger Seat) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams > Occupant Classification Sensor (OCS) Module C3159 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams > Occupant Classification Sensor (OCS) Module > Page 8032 C3291 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams > Occupant Classification Sensor (OCS) Module > Page 8033 C3292 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Description and Operation > OCS System Seat Occupant Sensor: Description and Operation OCS System OCS System The OCS system is found only on the front passenger seat. The front passenger OCS system is comprised of the following: 2 OCS rails (weight sensors) that are mounted to each side of the seat track; an OCS module (electronic control unit) which is mounted to the electrical bracket underneath the seat cushion pan. The weight of any occupant or object on the front passenger seat is electronically communicated to the OCS module. The OCS system is also used for operation of the passenger Belt Minder. To deactivate or reactivate the passenger Belt Minder feature, refer to Seat Belt Systems or the owner's literature. The components that make up the OCS system, OCS module, inboard OCS rail and outboard OCS rail are serviced separately. When the front passenger seat is removed for service, the Zero Seat Weight Test must be carried out after the installation of the front passenger seat. When a OCS system component is installed new, the System Reset must be carried out after the installation of the front passenger seat. The Zero Seat Weight Test and/or System Reset must be carried out only as instructed to do so. OCS Rails (Weight Sensors) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Description and Operation > OCS System > Page 8036 The components that make up the OCS system (OCS system module, inboard OCS rail and outboard OCS rail) are serviced separately. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Description and Operation > OCS System > Page 8037 Seat Occupant Sensor: Description and Operation Occupant Classification Sensor (OCS) System OCCUPANT CLASSIFICATION SENSOR (OCS) SYSTEM The occupant classification system (OCS) system is standard equipment on all front passenger seats. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Description and Operation > Page 8038 Seat Occupant Sensor: Service and Repair OCCUPANT CLASSIFICATION SENSOR Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Description and Operation > Page 8039 Part 2 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. - The occupant classification sensor rails have a built-in strain gauge which may operate incorrectly if an occupant classification sensor rail is dropped by itself, dropped when installed to the front passenger seat or dropped when installed to a front passenger seat track assembly. Use care when handling an occupant classification sensor rail or when installed to the front passenger seat of front passenger seat track assembly. Failure to follow these instructions may increase the risk of personal injury or death in a crash. - Do not disassemble the occupant classification sensor rail, tighten or loosen any of the nuts and bolts installed to the occupant classification sensor rail body. Only the 8 bolts that attach the 2 occupant classification sensor rails to the seat track should be removed and installed. Failure to follow these instructions may increase the risk of personal injury or death in a crash. - Oil, grease, water or foreign material on or in the occupant classification sensor rail may cause the supplemental restraint system to deploy incorrectly. Never allow oil, grease, water or foreign material to get on or into the occupant classification sensor rail. Failure to follow these instructions may increase the risk of personal injury or death in a crash. - To reduce the risk of personal injury, do not use any memory saver devices. 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: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - 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. - Outboard occupant classification sensor (OCS) rail shown, inboard similar. 1. Remove the passenger seat and depower the system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Description and Operation > Page 8040 2. CAUTION: Push only on the tip of the occupant classification sensor (OCS) electrical connector release tab to release the electrical connector. Do not insert the tool too deep into the OCS electrical connector or damage to the electrical connector may occur. NOTE: Note the position and the routing of the OCS rail electrical wiring, connector and wiring retainers for installation. On the affected side, detach the 2 OCS rail wiring retainers. Then using a suitable tool, release the tab and disconnect the OCS rail electrical connector. 3. If equipped, disconnect the power seat track motor electrical connector. 4. Move the seat to the forward most position. - If equipped with a power seat track, apply power and ground to the pins shown. 5. Remove the 2 rear bolts from the affected OCS rail. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Description and Operation > Page 8041 6. Move the seat to the rearward most position. - If equipped with a power seat track, apply power and ground to the pins shown. 7. NOTE: Note the position of where the locator tab on the OCS rail goes through the OCS rail shield and into the rear mounting point of the seat track for installation. Remove the 2 front bolts and the affected OCS rail and shield. Installation NOTE: If installing a new seat track, position the seat track where the seat will be in the rearward most position before starting installation of the OCS rails. 1. WARNING: The occupant classification sensor rail shield is an aid to prevent foreign material and contaminants from entering the occupant classification sensor rail. Make sure the occupant classification sensor rail shield is present, is not damaged and is correctly installed to the occupant classification sensor rail. Failure to follow these instructions may increase the risk of personal injury or death in a crash. NOTE: Make sure the OCS rail shield is seated correctly on the OCS rail. Align the locator tab to the shield. Position the OCS rail shield on the OCS rail. Then position the OCS rail and shield on the seat track while noting the correct installation of the OCS rail locator tab into the seat track. 2. NOTE: To make sure of correct installation, the OCS rail bolts must be installed in the sequence shown. While holding the OCS rail and shield firmly in position, install the OCS rail front mounting position rear bolt. Tighten to 25 Nm (18 lb-ft). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Description and Operation > Page 8042 3. While still holding the OCS rail and shield firmly in position, install the OCS rail front mounting position front bolt. - Tighten to 25 Nm (18 lb-ft). 4. Move the seat to the forward most position. - If equipped with a power seat track, apply power and ground to the pins shown. 5. Install the 2 rear OCS rail bolts. - Tighten to 25 Nm (18 lb-ft). 6. NOTE: Make sure to route the OCS rail wiring and install the 2 wiring retainers as noted during removal. Connect the OCS rail electrical connector. Then route the OCS rail wiring and attach the 2 wiring retainers. 7. Center the seat track to the seat cushion pan. - If equipped with a power seat track, apply power and ground to the pins shown. 8. If equipped, connect the power seat track motor electrical connector. 9. Install the passenger seat and repower the supplemental restraints system (SRS). Do not prove out the SRS at this time. 10. Carry out the appropriate procedure after installation of an OCS system component. - If installing the original OCS system component, carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. See: Air Bag Systems/Testing and Inspection/Component Tests and General Diagnostics/Occupant Classification Sensor (OCS) System Zero Seat Weight Test - If installing a new OCS system component, carry out the Occupant Classification Sensor (OCS) System Reset procedure and prove out the SRS. See: Air Bag Systems/Service and Repair Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Service and Repair Seat Position Sensor: Service and Repair SEAT POSITION SENSOR Removal and 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a SRS component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a SRS fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - Power seat track seat position sensor shown, manual seat track position sensor similar. 1. Position the front seat to the rearmost and upward position. 2. Depower the system. 3. Disconnect the seat position sensor electrical connector. 4. WARNING: The tightening torque of the seat position sensor retaining bolt is critical for correct system operation. NOTE: Note the position of the seat position sensor locating tab for installation. Remove the bolt and the seat position sensor. To install, tighten to 6 Nm (53 lb-in). 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Service and Repair > Page 8046 6. Repower the system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations View 151-19 (Driver Seat) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 8050 C356 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8056 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Service and Repair Global Positioning System Antenna: Service and Repair GLOBAL POSITIONING SYSTEM (GPS) ANTENNA Removal and Installation 1. Remove the audio unit. 2. Remove the passenger air bag module. 3. Remove the GPS antenna screw. 4. Release the antenna cable locators and remove the GPS antenna. 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Cable - Satellite Radio Antenna Cable: Service and Repair Antenna Cable - Satellite Radio ANTENNA CABLE - SATELLITE RADIO Removal and Installation 1. Remove the RH A-pillar trim panel. 2. Disconnect the satellite antenna electrical connector. - Separate the satellite radio antenna cable pin-type retainers from the A-pillar and instrument panel. 3. Lower the glove compartment. - Open the glove compartment door. - Press the tabs inward and lower the glove compartment. 4. Disconnect the satellite radio antenna cable from the satellite radio receiver. 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Cable - Satellite Radio > Page 8066 Antenna Cable: Service and Repair Antenna Lead-In Cable ANTENNA LEAD-IN CABLE Removal and Installation 1. Remove the audio unit. 2. Lower the glove compartment door. 3. NOTE: Release the pin-type retainers. Disconnect the antenna lead-in cable connection and remove the antenna lead-in cable. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transmitter > Component Information > Service and Repair Alarm System Transmitter: Service and Repair PASSIVE ANTI-THEFT SYSTEM (PATS) TRANSCEIVER Removal and Installation 1. Remove the steering column cover. 2. Remove the ignition lock cylinder. 3. Remove the 3 screws and the lower steering column shroud. 4. Remove the PATS transceiver. 1 Release the 2 tabs. 2 Disconnect the electrical connector. 5. NOTE: Replacement of the PATS transceiver does not require the PATS keys to be programmed into the instrument cluster again. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transmitter > Component Information > Service and Repair > Page 8071 To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Diagrams C2007 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Locations View 151-21 (Driver Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Locations > Page 8079 C500 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Locations > Page 8080 Keyless Entry Key-Pad: Testing and Inspection KEYLESS ENTRY KEYPAD CODE PROGRAMMING NOTE: A maximum of 3 personal entry codes can be programmed into the vehicle. The personal entry codes can be associated with up to two memory seat/adjustable pedal settings. 1. Enter the permanent factory keyless entry keypad code. 2. Press the 1/2 button within 5 seconds to activate the programming mode. Holding the 1/2 button for more than 2 seconds after activation erases all the stored customer codes. The existing codes do not need to be erased to program a new code. 3. Within 5 seconds, enter the new 5-digit keyless entry keypad code. 4. Press the 1/2, 3/4, or 5/6 to indicate which of the three personal entry code positions is to be programmed. 5. The door locks lock and unlock to confirm the new code is programmed. 6. To program an additional personal entry code, REPEAT steps 2 through 4. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Locations > Page 8081 Keyless Entry Key-Pad: Service and Repair KEYLESS ENTRY KEYPAD Removal and Installation 1. Position the front window glass to the full down position. 2. Position the door glass top run aside to access the door pillar trim panel screws. 3. Remove the 3 door pillar trim panel screws and the door pillar trim panel. 4. Disconnect the electrical connector and remove the keyless entry keypad from the door pillar trim panel. 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry Transmitter Programming Keyless Entry Transmitter: Testing and Inspection Remote Keyless Entry Transmitter Programming REMOTE KEYLESS ENTRY TRANSMITTER PROGRAMMING NOTE: - All remote keyless entry (RKE) transmitters must be programmed at the same time. - Programming of the RKE transmitters can be accomplished using a scan tool or by carrying out the following steps: 1. The vehicle must be electronically unlocked before entering program mode using the RKE transmitter, keyless entry keypad (if equipped) or door lock control switch while the driver door is open. 2. Turn the key from OFF to RUN 8 times within 10 seconds, with the eighth turn ending in RUN. If the module successfully enters the program mode, it locks and then unlocks all doors. 3. Within 20 seconds, press any button on an RKE transmitter, and the doors lock and then unlock to confirm that each RKE transmitter is programmed. Repeat this step for each RKE transmitter. 4. If the door locks do not respond for any RKE transmitter, wait several seconds and press the button again. If the door locks still fail to respond, refer to Inspection and Verification. Make sure that no more than the maximum number of 6 RKE transmitters are attempted to be programmed. See: Body and Frame/Locks/Power Locks/Testing and Inspection/Initial Inspection and Diagnostic Overview/Inspection and Verification 5. Exiting the programming mode is accomplished if one of the following occurs: - The key transitions to the OFF position. Twenty seconds have passed since entering programming mode or since the last RKE transmitter was programmed. - The maximum number of 6 RKE transmitters have been programmed. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry Transmitter Programming > Page 8086 Keyless Entry Transmitter: Testing and Inspection Autolock and Horn Chirp Programming AUTOLOCK AND HORN CHIRP PROGRAMMING Autolock Programming Using the Keyless Entry Keypad 1. Close all doors and windows. 2. Confirm that the ignition key is OFF. 3. Enter the 5-digit permanent entry code into the keyless entry keypad. 4. Within 5 seconds of entering the code, press and hold the 3/4 button on the keyless entry keypad. 5. Within 5 seconds of Step 3, and while holding the 3/4 button, press the 7/8 button on the keyless entry keypad and release it. 6. NOTE: If the autolock is disabled, the horn chirps once. If the autolock feature is enabled, the horn chirps once shortly and then sounds a second time with a longer sound of the horn once the above sequence is completed. Within 5 seconds of Step 3, release the 3/4 button on the keyless entry keypad. Autolock Programming Using the Ignition Lock Cylinder 1. Close all doors and windows. 2. Confirm that the ignition key is OFF. 3. NOTE: Steps 5 through 9 must be carried out within 30 seconds. Turn the ignition key from OFF to RUN. 4. Press the door lock control switch UNLOCK button 3 times. 5. Turn the ignition key from RUN to OFF. 6. Press the door lock control switch UNLOCK button 3 times. 7. Turn the ignition key from OFF to RUN. 8. Verify the horn chirps. This indicates the enable/disable mode and now is ready to accept program changes. 9. Press the door lock control switch UNLOCK button then the LOCK button 1 time to command the module to toggle the autolock/relock feature. 10. Verify that the horn chirps. There should be 1 chirp indicating that autolock/relock feature has been disabled. If 1 chirp is heard, followed by a longer sound of the horn, the autolock/relock feature has just been enabled. 11. Turn the key to the OFF position or wait 2 minutes to exit the enable/disable mode. 12. Verify that the horn chirps once to indicate that a feature has been changed and that autolock/relock has been toggled. Auto-Unlock Programming Using the Keyless Entry Keypad 1. Close all doors and windows. 2. Confirm that the ignition key is OFF. 3. Enter the 5-digit permanent entry code into the keyless entry keypad. 4. Within 5 seconds of entering the code, press and hold the 3/4 button on the keyless entry keypad. 5. Within 5 seconds of Step 3, and while holding the 3/4 button, press the 7/8 button twice on the keyless entry keypad and release it. 6. NOTE: If the auto-unlock is disabled, the horn chirps once. If the auto-unlock feature is enabled, the horn chirps twice. Within 5 seconds of Step 3, release the 3/4 button on the keyless entry keypad. Auto-Unlock Programming Using the Ignition Lock Cylinder 1. Close all doors and windows. 2. Confirm that the ignition key is OFF. 3. NOTE: Steps 5 through 9 must be carried out within 30 seconds. Turn the ignition key from OFF to RUN. 4. Press the door lock control switch UNLOCK button 3 times. 5. Turn the ignition key from RUN to OFF. 6. Press the door lock control switch UNLOCK button 3 times. 7. Turn the ignition key from OFF to RUN. 8. Verify the horn chirps. This indicates the enable/disable mode and now is ready to accept program changes. 9. Press the door lock control switch LOCK button then the UNLOCK button 1 time to command the module to toggle the auto-unlock feature. 10. Verify that the horn chirps. There should be 1 chirp indicating that auto-unlock feature has been disabled. If 1 chirp is heard, followed by a longer sound of the horn, the auto-unlock feature has just been enabled. 11. Turn the key to the OFF position or wait 2 minutes to exit the enable/disable mode. 12. Verify that the horn chirps once to indicate that a feature has been changed and that auto-unlock has been toggled. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > Procedures Keyless Entry Transmitter: Procedures Remote Memory Activation REMOTE MEMORY ACTIVATION 1. Position the driver seat and adjustable pedals to the desired position. 2. Press the set button on the lower center of the instrument panel. 3. Within 5 seconds press one control on the remote keyless entry (RKE) transmitter and then the 1 or 2 button on the lower center of the instrument panel to associate the RKE transmitter to the driver 1 or the driver 2 position. This stores the configuration for driver 1 or driver 2. 4. If a second memory setting is desired, repeat the procedure with the second RKE transmitter. Remote Memory Deactivation REMOTE MEMORY DEACTIVATION 1. Press the set button on the lower center of the instrument panel. 2. Within 5 seconds press one control on the remote keyless entry (RKE) transmitter and then the set button on the lower center of the instrument panel to associate the RKE transmitter to the driver 1 or the driver 2 position. 3. If a second memory setting is desired to be deactivated, repeat the procedure with the second RKE transmitter. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > Procedures > Page 8089 Keyless Entry Transmitter: Removal and Replacement TAILGATE LATCH REMOTE CONTROL Removal and Installation 1. Open and support the tailgate. 2. Remove the 7 bolts, the 4 pin-type retainers and the tailgate access panel. - To install, tighten to 5 Nm (44 lb-in). 3. Open the 2 clips and release the 2 tailgate latch actuating rods from the tailgate remote control. 4. Release the 2 tailgate latch actuating rod locators from the tailgate. 5. Remove the 2 nuts and the tailgate remote control. - To install, tighten to 9 Nm (80 lb-in). 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 View 151-17 (Right Rear, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 8094 View 151-29 (Rear End) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 8095 Parking Assist Control Module: Diagrams C4014 C4226 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 8096 Parking Assist Control Module: Service and Repair PARKING AID MODULE Removal and Installation 1. Disconnect the parking aid module bumper harness from the body harness. 2. Remove the rear bumper cover. 3. Remove the 4 insulator-to-bumper cover nuts and the insulator from the bumper cover. 4. Disconnect the parking aid module bumper harness from the parking aid module. 5. Remove the 2 parking aid module bracket bolts. 6. Remove the parking module bracket assembly. 7. Release the module tabs from the bracket and remove the module. 8. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations View 151-29 (Rear End) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left C4009 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 8102 C4011 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 8103 C4010 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 8104 C4012 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Warning Indicator > Component Information > Diagrams C4015 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Locations View 151-11 (behind Dash Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Locations > Page 8111 C253 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Locations > Page 8112 Driver/Vehicle Information Display: Description and Operation INFORMATION AND MESSAGE CENTER The message center is a liquid crystal display (LCD), integrated into the instrument cluster. The message center functions are controlled by the TRIP/RESET button on base instrument clusters, and by the message center switches on high series instrument clusters. The base series instrument cluster message center has a display format of 2 lines x 12 characters, and the high series instrument cluster message center has a display format of 4 lines x 12 characters. The message center displays important vehicle information by constantly monitoring different vehicle systems. The message center notifies the driver of a potential vehicle problem by displaying a warning message pertaining to the system in which a fault has been detected. Refer to the Owner's Literature for operating instructions. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Driver/Vehicle Information Display: Initial Inspection and Diagnostic Overview Inspection and Verification INSPECTION AND VERIFICATION 1. Verify the customer concern. Visual Inspection Chart 2. Visually inspect for obvious signs of mechanical or electrical damage. 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. NOTE: Make sure to use the latest scan tool software release. If the cause is not visually evident, connect the scan tool to the data link connector (DLC). 5. NOTE: The vehicle communication module (VCM) LED prove-out confirms power and ground from the DLC are provided to the VCM. If the scan tool does not communicate with the VCM: Check the VCM connection to the vehicle. - Check the scan tool connection to the VCM. - Refer to Information Bus (Module Communications Network), No Power To The Scan Tool, to diagnose no communication with the scan tool. 6. If the scan tool does not communicate with the vehicle: - Verify the ignition key is in the ON position. - Verify the scan tool operation with a known good vehicle. - Refer to Information Bus (Module Communications Network) to diagnose no response from the powertrain control module (PCM). 7. Carry out the network test: - If the scan tool responds with no communication for one or more modules, refer to Information Bus (Module Communications Network). - If the network test passes, retrieve and record the continuous memory DTCs. 8. Clear the continuous DTCs and carry out the self-test diagnostics for the instrument cluster. 9. If the DTCs retrieved are related to the concern, go to the Instrument Cluster Diagnostic Trouble Code (DTC) Chart. For all other DTCs, refer to Body Control Systems (Multifunction Electronic Control Module). See: Diagnostic Trouble Code Descriptions 10. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Principles of Operation PRINCIPLES OF OPERATION The message center electronic functions use both hardwired inputs and the controller area network (CAN) to transmit and receive information. It is very important to understand: - where the input (command) originates. - all the information (messages) necessary in order for a feature to operate. - which module(s) receive(s) the input or command message. - if the module which received the input (message) controls the output of the feature, or if it outputs a message over the CAN circuit to another module. - which module controls the output of the feature. The message center provides the following features: - Information displays - Setup displays - System check messages - Warning messages Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8115 The message center information can be selected through the TRIP/RESET button (base cluster) and by the INFO, SETUP, and RESET buttons (high series cluster). Information Displays (Base Instrument Cluster) The information displays are non-timed modes. The selected mode remains on until the driver presses a message center switch to change the mode, or until it is overridden by another mode. The information display modes are: Odometer/trip odometer, compass headings - Distance to empty - Average fuel economy - Setup menu Information Displays (High Series Instrument Cluster) The information displays are non-timed modes. The selected mode remains on until the driver presses a message center switch to change the mode, or until it is overridden by another mode. The information display modes are: Odometer/trip odometer, compass headings, outside air temperature display (with dual electronic automatic temperature control) - Distance to empty - Average fuel economy - Instantaneous fuel economy - Fuel used - Trip elapsed drive time - Blank Setup Displays (Base Instrument Cluster) The setup displays are timed modes and terminate after a finite interval. Press the TRIP/RESET button to scroll through the SETUP MENU display sequence. If the TRIP/RESET button is not pressed within 4 seconds, the message center returns to the INFO MENU. The setup display modes are: AWD lock (vehicles equipped with traction control with roll stability control [RSC] only) - System check - Units (English/metric) - Language - Autolamp - Autolock - Auto-unlock - Parking aid - Oil life start value Setup Displays (High Series Instrument Cluster) The setup displays are timed modes and terminate after a finite interval. Press the SETUP button for the following displays: AWD lock (vehicles equipped with traction control with roll stability control [RSC] only) - System check - Units (English/metric) - Language - Autolamp - Autolock - Auto-unlock - Running boards (if equipped) - Easy entry/exit seat - Parking aid - Compass zone - Compass calibration - Oil life start value System Check Displays Selecting this function from the SETUP MENU causes the message center to cycle through each of the systems being monitored. For each of the monitored systems, the message center indicates either an OK message or a warning message for 2 seconds. For base instrument clusters, the TRIP/RESET button must be held down after pressing the TRIP/RESET button to cycle the messages through each of the systems being monitored. For high series instrument clusters, pressing the RESET control switch cycles the message center through each of the systems being monitored. The system check report is as follows: OIL LIFE RESET - CHARGING SYSTEM - WASHER FLUID - DOOR AJAR - EXTERIOR LAMPS - BRAKE FLUID LEVEL - PARK BRAKE - FUEL LEVEL Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8116 System Warnings The system warnings alert the operator to possible problems or malfunctions in the vehicle operating systems. The message center displays the last selected feature if there are no more warning messages. This allows the operator full functionality of the message center after acknowledgement of the warning message by pressing the RESET button and clearing the message. The warning messages are divided into 4 categories: They cannot be cleared until the condition is corrected. - They reappear on the display 10 minutes from the reset if the condition has not been corrected. - They do not reappear until an ignition OFF-ON cycle has been completed. - They reappear if the condition clears then reoccurs within the same ignition ON-OFF cycle. The warning displays that cannot be reset are: DOOR AJAR - CLEAR OBJECTS BY PASS SEAT The warning messages that reoccur after 10 minutes are: CHECK CHARGING SYSTEM - FUEL LEVEL LOW - PARK BRAKE ENGAGED - CHECK BRAKE SYSTEM The warning messages that display whenever the ignition switch is turned from the OFF position to the ON position are: CHECK PARK AID - BRAKE FLUID LEVEL LOW - CHECK HEADLAMP - CHECK HIGHBEAM - CHECK TURN LAMP - WASHER FLUID LOW LEVEL - OIL CHANGE REQUIRED - ENGINE OIL CHANGE SOON The warning messages that return after a condition has cleared then reoccurs within the same ignition ON-OFF cycle are: LIFTGATE/GLASS AJAR - LOW TIRE PRESSURE - TIRE MONITOR FAULT - TIRE SENSOR FAULT - TRAIN TIRES - TIRES TRAINED - TIRES NOT TRAINED Outside Air Temperature Sensor (Base Instrument Cluster without Electronic Automatic Temperature Control [EATC]) The base instrument cluster receives the outside air temperature data from the outside air temperature sensor. This data is then displayed on the message center. The outside air temperature sensor is located on the radiator core support behind the front grill assembly and is fastened with a pin-type retainer. If equipped with a high series instrument cluster, the outside air temperature data from the outside air temperature sensor is displayed in the electronic automatic temperature control (EATC) module. Compass The compass heading is displayed as one of N, NE, E, SE, S, SW, W and NW in the message center display. The compass reading may be affected when you drive near large buildings, bridges, power lines and powerful broadcast antenna. Magnetic or metallic objects placed in, on or near the vehicle may also affect compass accuracy. The compass sensor module is mounted behind the interior rear view mirror. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8117 B1255-B2097 / U2013 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8118 Driver/Vehicle Information Display: Symptom Related Diagnostic Procedures Symptom Chart (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8119 Symptom Chart (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8120 Symptom Chart (Part 3) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8121 Symptom Chart (Part 4) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8122 Symptom Chart (Part 5) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8123 Driver/Vehicle Information Display: Pinpoint Tests Test A: The Message Center Is Not Operating Correctly PINPOINT TEST A: THE MESSAGE CENTER IS NOT OPERATING CORRECTLY (HIGH SERIES INSTRUMENT CLUSTER) A1 A2 Normal Operation The message center functionality is controlled through the message center switch, which is hardwired to the instrument cluster through circuits CMC29 (GN/VT) and RMC32 (GN/BU). Possible Causes - Message center switch - Instrument cluster Test B: The Compass Is Inoperative PINPOINT TEST B: THE COMPASS IS INOPERATIVE. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8124 B1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8125 B2-B3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8126 B4 Normal Operation The compass sensor module receives voltage from the smart junction box (SJB) through circuit CBP18 (GY/OG) and is grounded through circuit GD143 (BK/VT). The compass sensor module communicates the vehicle direction to the instrument cluster, which is displayed in the message center. The compass sensor module uses circuits VMC30 (BU/GY) and VMC31 (YE/GN) to communicate to the instrument cluster. DTC B2097 - is a continuous memory DTC that sets in the instrument cluster if the data received from the compass module is invalid. DTC U2013 - is a continuous and on-demand DTC that sets if the instrument cluster fails to receive a response from the compass module after 4 consecutive attempts. Possible Causes - Fuse - Circuit CBP18 (GY/OG) open - Circuit GD143 (BK/VT) open - Circuit VMC30 (BU/GY) open or short to ground - Circuit VMC31 (YE/GN) open or short to ground -- Compass sensor module Test C: The Compass Is Inaccurate PINPOINT TEST C: THE COMPASS IS INACCURATE C1-C2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8127 C2 Normal Operation The compass sensor module communicates the vehicle direction to the instrument cluster to display in the message center. Possible Causes - Compass out of calibration - Zone setting - Vehicle is magnetized - Compass sensor module Test D: The Message Center Switch Does Not Operate Correctly PINPOINT TEST D: THE MESSAGE CENTER SWITCH DOES NOT OPERATE CORRECTLY (HIGH SERIES INSTRUMENT CLUSTER) D1-D2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8128 D2-D4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8129 D4-D5 Normal Operation The message center switch uses circuit CMC29 (GN/VT) to communicate the requested switch function to the instrument cluster message center. The message center switch is grounded through circuit RMC32 (GN/BU). Each message center switch uses a different resistance value allowing the instrument cluster to determine which switch is pressed. Possible Causes - Circuit CMC29 (GN/VT) open, short to ground or voltage - Circuit RMC32 (GN/BU) open - Message center switch - Instrument cluster Test E: The Outside Air Temperature Display Does Not Operate Correctly PINPOINT TEST E: THE OUTSIDE AIR TEMPERATURE DISPLAY DOES NOT OPERATE CORRECTLY Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8130 E1-E3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8131 E3-E5 NOTE: The outside air temperature display is only available in base instrument clusters without electronic automatic temperature control (EATC). Normal Operation The outside air temperature sensor is hardwired to the instrument cluster through circuits VH407 (YE/GN) and RMC32 (GN/BU). The message center displays the outside air temperature upon receipt of the outside air temperature data. DTC B1255 - is a continuous and on-demand DTC that sets if the instrument cluster detects an open on the outside air temperature sensor input circuit VH407 (YE/GN). If the instrument cluster detects an open on the outside air temperature input, the instrument cluster defaults the display to 23.5° Celsius (75°F). DTC B1257 - is a continuous and on-demand DTC that sets if the instrument cluster detects a short to ground on the outside air temperature sensor input circuit VH407 (YE/GN). If the instrument cluster detects a short to ground on the outside air temperature input, the instrument cluster defaults Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8132 the display to 23.5°Celsius (75°F). Possible Causes - Circuit VH407 (YE/GN) open or short to ground - Circuit RMC32 (GN/BU) open - Ambient air temperature sensor - Instrument cluster Test F: The Washer Fluid Low Level Warning Is Inoperative PINPOINT TEST F: THE WASHER FLUID LOW LEVEL WARNING IS INOPERATIVE F1-F2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8133 F3-F6 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8134 F6-F7 Normal Operation The instrument cluster is hardwired to the low washer fluid switch (part of the windshield washer reservoir) through circuit CMC20 (VT). The low washer fluid switch closes when the washer fluid level is approximately 1/3 full, providing a ground to the instrument cluster through circuit GD108 (BK/VT) and turning on the WASHER FLUID LOW LEVEL warning. When the washer fluid is above the low level, the low washer fluid switch opens, removing the ground to the instrument cluster, and the WASHER FLUID LOW LEVEL warning turns off. Possible Causes - Circuit GD108 (BK/VT) open - Circuit CMC20 (VT) open or short to ground - Washer fluid level switch (part of the windshield washer reservoir) - Instrument cluster Test G: The Check Charging System Warning Is Inoperative PINPOINT TEST G: THE CHECK CHARGING SYSTEM WARNING IS INOPERATIVE G1-G2 Normal Operation The charging system warning indicator is controlled by the instrument cluster based upon data received from the powertrain control module (PCM) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8135 over the high speed controller area network (HS-CAN). Possible Causes - Charging system - Instrument cluster Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures Driver/Vehicle Information Display: Procedures Message Center Cluster OIL LIFE RESET - MESSAGE CENTER CLUSTER NOTE: The oil life calculation is set at a maximum of approximately 8,000 km (5,000 miles) or 180 days. 1. Press and release the SETUP button until the message center displays PRESS RESET TO BEGIN SYSTEM CHECK. 2. Press and release the RESET button until the message center displays HOLD RESET IF NEW OIL. 3. Press and hold the RESET button for 2 seconds and release to reset the oil life to 100%. 4. The message center displays SETUP MENU HOLD RESET. Base Instrument Cluster OIL LIFE RESET - BASE INSTRUMENT CLUSTER NOTE: Oil life calculation is set at a maximum of approximately 8,000 km (5,000 miles) or 180 days. 1. Press and release the TRIP/RESET button until the message center displays SETUP MENU HOLD RESET. 2. Press and hold the TRIP/RESET button for 2 seconds until the message center displays RESET FOR SYSTEM CHECK. 3. Press and hold the TRIP/RESET button for 2 seconds until the message center displays OIL LIFE xx% RESET IF NEW. 4. Press and release the TRIP/RESET button until the message center displays HOLD RESET IF NEW OIL. 5. Press and hold the TRIP/RESET button for 2 seconds and release to reset the oil life to 100%. 6. Message center briefly displays OIL CHANGE SET TO 100%. Message Center Cluster OIL LIFE START VALUE - MESSAGE CENTER CLUSTER NOTE: The oil life start value is used to reset the oil life value back to the maximum of approximately 8,000 km (5,000 miles) if the value was previously changed or to lower the value from the maximum (8,000 km [5,000 miles]) in 10% increments down to 10%. 1. Press and release the SETUP button until the message center displays OIL LIFE START VALUE SET TO XX%. 2. Press and release the RESET button to lower the percentage by 10% (down to 10%) for each button press or return the value to 100%. Base Instrument Cluster OIL LIFE START VALUE - BASE INSTRUMENT CLUSTER NOTE: The oil life start value is used to reset the oil life value back to the maximum of approximately 8,000 km (5,000 miles) if the value was previously changed or to lower the value from the maximum (8,000 km [5,000 miles]) in 10% increments down to 10%. 1. Press and release the TRIP/RESET button until the message center displays SETUP MENU HOLD RESET. 2. Press and hold the TRIP/RESET button for 2 seconds until the message center displays RESET FOR SYSTEM CHECK. 3. Press and release the TRIP/RESET button until the message center displays OIL LIFE SET TO XX%. 4. Press and hold the TRIP/RESET button for 2 seconds to lower the percentage by 10% (down to 10%) for each button press-and-hold or return the value to 100%. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 8138 Driver/Vehicle Information Display: Removal and Replacement MESSAGE CENTER SWITCH Removal and Installation 1. Remove the instrument panel center finish panel. 2. Press the retaining tabs and remove the message center switch. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Page 8139 Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Diagrams C3337 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Diagrams > Page 8144 Auxiliary Input / Output Jack: Service and Repair AUDIO INPUT JACK Removal and Installation 1. Remove the floor console finish panel. 2. Release the tabs and remove the audio input jack. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Diagrams C949 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Diagrams > Page 8148 DVD Player: Service and Repair DIGITAL VERSATILE DISC (DVD) PLAYER Removal NOTE: Programmable module installation (PMI) only needs to be carried out if the DVD player is being replaced. 1. Upload the DVD player configuration to the scan tool. 2. NOTE: Open the DVD player display. Remove the 4 screws. 3. Remove the DVD player. - Pull down on the sides of the DVD player to disengage the clips from the bracket. - Using a suitable tool, push the rear most U-hook forward and release the U-hooks. - Hang the DVD player on the J-hooks and disconnect the electrical connector. - Remove the DVD player from the J-hooks. Installation 1. Hang the DVD player on the J-hooks. 2. Connect the electrical connector. 3. Remove the DVD player from the J-hooks. 4. NOTE: Tilt the DVD player, as necessary, to align it correctly. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Diagrams > Page 8149 Align the left side guide pin with the left side locating hole. 5. Lift up the right side of the DVD player and engage the U-hooks. 6. Install the 4 screws. 7. Push on the left and right sides of the DVD player to engage the clips. 8. Download the DVD player configuration from the scan tool. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Locations View 151-26 (Roof) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Locations > Page 8153 Garage Door Opener Transmitter: Diagrams C928 C9037 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Locations > Page 8154 Garage Door Opener Transmitter: Description and Operation UNIVERSAL TRANSMITTER The universal transmitter, located in the overhead console, provides a convenient way to substitute up to 3 hand-held transmitters with a single built-in device. The universal transmitter can learn the radio frequency codes of most current transmitters. The universal transmitter: - operates garage doors, gates and home/office lighting and security systems. - learns and transmits the radio frequency of up to 3 hand-held transmitters from any of the systems mentioned above. - is powered by the vehicle battery and charging system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 INSPECTION AND VERIFICATION 1. Verify the customer concern. 2. Visually inspect the following for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical Universal transmitter - Receiver unit 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 cause is not visually evident, verify the symptom. GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8157 Symptom Chart Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8158 Garage Door Opener Transmitter: Pinpoint Tests PINPOINT TEST A: THE UNIVERSAL TRANSMITTER IS INOPERATIVE A1-A5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8159 A5 Continued Normal Operation The universal transmitter is integral to the overhead console. The universal transmitter can be programmed to operate up to 3 garage doors, entry gates, security systems, and home or office lighting. Voltage is supplied to the universal transmitter through circuit CLN01 (GN/VT) and grounded on circuit GD133 (BK). Possible Causes - Circuit CLN01 (GN/VT) open - Circuit GD133 (BK) open - Receiver unit - Universal transmitter Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Erasing Channels Garage Door Opener Transmitter: Service and Repair Erasing Channels ERASING CHANNELS 1. NOTE: Individual channels cannot be erased, but can be reprogrammed using the procedures for programming. To erase all 3 programmed channels, hold down the 2 outside buttons until the red light begins to flash (20-30 seconds). Release both buttons. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Erasing Channels > Page 8162 Garage Door Opener Transmitter: Service and Repair Universal Transmitter Programming Universal Transmitter Programming 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 universal 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. Failure to follow these instructions may result in personal injury. 1. Verify the hand-held transmitter is operative. 2. Prepare for programming the universal transmitter by erasing all 3 channels by holding down the 2 outside buttons until the red light begins to flash (20-30 seconds). Release both buttons. 3. Select 1 of the 3 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. NOTE: During programming, the hand-held transmitter may automatically stop transmitting after 2 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 pressing the hand-held transmitter button every 2 seconds. Use both hands to press the hand-held transmitter button and the desired button on the universal transmitter. Do not release either button. 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, press the appropriate button on the universal transmitter. The red light is on while the signal is being transmitted. 8. To program additional hand-held transmitters repeat Steps 3-6. 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. 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 press the button to confirm the universal transmitter is trained to the receiver. 5 The garage door opener should recognize the universal transmitter. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Page 8163 Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Service and Repair Global Positioning System Antenna: Service and Repair GLOBAL POSITIONING SYSTEM (GPS) ANTENNA Removal and Installation 1. Remove the audio unit. 2. Remove the passenger air bag module. 3. Remove the GPS antenna screw. 4. Release the antenna cable locators and remove the GPS antenna. 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations View 151-19 (Driver Seat) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 8172 Memory Positioning Module: Diagrams C341A C341B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 8173 C341C Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 8174 Memory Positioning Module: Description and Operation Memory Adjustable Pedal Operation The adjustable pedals with memory feature is controlled by using the memory switches or the remote keyless entry (RKE) transmitter. The exterior mirror and power driver seat positions are also stored and recalled with the power adjustable pedal positions. The system can store 3 memory settings. Driver Seat Module (DSM) The DSM controls the memory adjustable pedals. The DSM constantly monitors the systems under its control and records concerns in the form of diagnostic trouble codes (DTCs). A DTC can be retrieved with the scan tool through the data link connector (DLC). Memory Adjustable Pedal Operation The adjustable pedals with memory feature is controlled by using the memory switches or the remote keyless entry (RKE) transmitter. The exterior mirror and power driver seat positions are also stored and recalled with the power adjustable pedal positions. The system can store 3 memory settings. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Belt Tower Position Sensor > Component Information > Description and Operation Seat Belt Tower Position Sensor: Description and Operation SEAT TRACK POSITION SENSOR The seat track position sensor is a Hall-effect sensor located on the driver seat track. The seat track position sensor informs the RCM of the driver seat position. Based on programmed limits, the seat track position sensor will inform the RCM of the driver seat position. The RCM uses this information in determining the deployment rate of the dual-stage driver air bag module. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 8181 C2094 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Audio System - Pioneer Navigation Radio - Seek Inop Navigation System: Technical Service Bulletins Audio System - Pioneer Navigation Radio - Seek Inop TSB 06-25-3 11/30/06 PIONEER NAVIGATION RADIO - SEEK FUNCTION INOPERATIVE - SERVICE TIP FORD: 2006-2007 Five Hundred, Freestyle 2007 Fusion, Mustang 2006-2007 Explorer 2007 Edge, Expedition, Explorer Sport Trac, F-150 LINCOLN: 2006 Zephyr 2007 MKZ, Mark LT, MKX, Navigator MERCURY: 2006-2007 Montego 2007 Milan 2006-2007 Mountaineer ISSUE Some 2006-2007 vehicles equipped with a Pioneer Navigation Radio may appear to have a defective seek function. It may be reported that the radio Seek function is inoperative, Seek will not stop (keeps scrolling through stations) or the radio exhibits Poor FM reception. This may be due to a misunderstanding of how the operation of the PTY (Program Type) feature functions. The PTY feature filters out radio stations that do not fit a selected category of radio programming like: Top 40, Classical, and News. The result is a "continuous seek" condition if the feature is activated and no stations are found under the selected category. ACTION Follow the Service Procedure to identify the PTY (Program Type) setting. SERVICE PROCEDURE To confirm the PTY (Program Type) setting use the following steps: 1. Under MEDIA, select the FM tab. (If you do not see an RDS and PTY button, push the SHOW OPTIONS buttons). 2. Verify RDS and PTY are enabled by the buttons being illuminated. If the text, above the SET PTY button says anything other than ALL, the unit is filtering for radio stations that transmit RDS text and are categorized as the selected Program Type, like: Top 40, Classical, and News. (See Figure 1) 3. To change the setting, either press the SET PTY button and select ALL. Or disable the PTY feature by pushing the PTY button. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Audio System - Pioneer Navigation Radio - Seek Inop > Page 8186 DEALER CODING CONDITION BASIC PART NO. CODE 18806 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions Navigation System: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8189 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8190 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8191 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8192 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8193 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8194 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8195 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8196 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8197 Navigation System: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8198 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8199 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8200 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8201 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8202 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8203 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8204 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8205 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8206 Navigation System: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 130-1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8207 130-2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8208 130-3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8209 130-4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8210 130-5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Diagrams > Diagram Information and Instructions > Page 8211 130-6 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. See: Diagrams/Components/Component Location Views Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Module > Component Information > Description and Operation Pedal Positioning Module: Description and Operation Adjustable Pedals Using the adjustable pedal switch located on the instrument panel, the driver can adjust the brake and accelerator pedals for a more comfortable driving position. For removal and installation of the adjustable pedals, refer to Brake Pedal and Bracket. Adjustable Pedal Operation The adjustable pedals with or without memory feature are operational with the ignition switch in the ON or OFF position. The pedals are adjusted forward or rearward using the adjustable pedal switch. Memory Adjustable Pedal Operation The adjustable pedals with memory feature is controlled by using the memory switches or the remote keyless entry (RKE) transmitter. The exterior mirror and power driver seat positions are also stored and recalled with the power adjustable pedal positions. The system can store 3 memory settings. Driver Seat Module (DSM) The DSM controls the memory adjustable pedals. The DSM constantly monitors the systems under its control and records concerns in the form of diagnostic trouble codes (DTCs). A DTC can be retrieved with the scan tool through the data link connector (DLC). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations Pedal Positioning Motor: Locations View 151-1 (Engine Compartment - 4.0L, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations > Page 8219 View 151-2 (Engine Compartment - 4.0L, (2 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations > Page 8220 Pedal Positioning Motor: Diagrams C2003 C2159 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations > Page 8221 Pedal Positioning Motor: Service and Repair Brake Pedal Motor Brake Pedal Motor Removal and Installation 1. Disconnect the accelerator and brake pedal drive cables from the adjustable pedal motor. 2. Disconnect the adjustable pedal motor electrical connector. 3. Remove the 2 adjustable pedal motor screws and then remove the adjustable pedal motor and drive cables as an assembly. ^ To install, tighten to 3 Nm (27 inch lbs.). 4. NOTE: Make sure the brake pedal and the accelerator pedal are in the same position before connecting the drive cable to the adjustable pedals. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations > Page 8225 C2089 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams C466 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Audio System - Pioneer Navigation Radio - Seek Inop Radio/Stereo: Technical Service Bulletins Audio System - Pioneer Navigation Radio - Seek Inop TSB 06-25-3 11/30/06 PIONEER NAVIGATION RADIO - SEEK FUNCTION INOPERATIVE - SERVICE TIP FORD: 2006-2007 Five Hundred, Freestyle 2007 Fusion, Mustang 2006-2007 Explorer 2007 Edge, Expedition, Explorer Sport Trac, F-150 LINCOLN: 2006 Zephyr 2007 MKZ, Mark LT, MKX, Navigator MERCURY: 2006-2007 Montego 2007 Milan 2006-2007 Mountaineer ISSUE Some 2006-2007 vehicles equipped with a Pioneer Navigation Radio may appear to have a defective seek function. It may be reported that the radio Seek function is inoperative, Seek will not stop (keeps scrolling through stations) or the radio exhibits Poor FM reception. This may be due to a misunderstanding of how the operation of the PTY (Program Type) feature functions. The PTY feature filters out radio stations that do not fit a selected category of radio programming like: Top 40, Classical, and News. The result is a "continuous seek" condition if the feature is activated and no stations are found under the selected category. ACTION Follow the Service Procedure to identify the PTY (Program Type) setting. SERVICE PROCEDURE To confirm the PTY (Program Type) setting use the following steps: 1. Under MEDIA, select the FM tab. (If you do not see an RDS and PTY button, push the SHOW OPTIONS buttons). 2. Verify RDS and PTY are enabled by the buttons being illuminated. If the text, above the SET PTY button says anything other than ALL, the unit is filtering for radio stations that transmit RDS text and are categorized as the selected Program Type, like: Top 40, Classical, and News. (See Figure 1) 3. To change the setting, either press the SET PTY button and select ALL. Or disable the PTY feature by pushing the PTY button. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Audio System - Pioneer Navigation Radio - Seek Inop > Page 8234 DEALER CODING CONDITION BASIC PART NO. CODE 18806 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Page 8235 C3290 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Page 8236 Radio/Stereo: Service and Repair SATELLITE RADIO RECEIVER Removal and Installation 1. Remove the RH cowl side trim panel. 2. NOTE: Lower the glove compartment door to access the top nut. Remove the bolt, the nut, and the satellite radio receiver. Disconnect the satellite radio antenna connector and the electrical connector. - To install, tighten to 7 Nm (62 lb-in). 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Locations View 151-30 (Steering Wheel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Locations > Page 8240 C2208 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Locations > Page 8241 Remote Control: Service and Repair STEERING WHEEL CONTROLS Removal and Installation 1. NOTE: - It is not necessary to remove the driver air bag module during this procedure. - When removing the steering wheel controls, disengage the RH side of the controls first. Using an appropriate tool, pry the steering wheel controls out of the steering wheel. 2. NOTE: Do not allow the electrical connector to fall back into the steering wheel. Remove the steering wheel controls. Disconnect the electrical connector. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Right Rear C802 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Right Rear > Page 8246 C612 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Right Rear > Page 8247 C523 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Right Rear > Page 8248 C702 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Speaker Speaker: Service and Repair Door Speaker DOOR SPEAKER Removal and Installation 1. Remove the door trim panel. 2. Remove the 4 screws and the door speaker. - Disconnect the electrical connector. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Speaker > Page 8251 Speaker: Service and Repair Subwoofer Speaker SUBWOOFER SPEAKER Removal and Installation 1. Remove the RH rear quarter trim panel. 2. Disconnect the electrical connector. 3. Remove the bolt, the 2 nuts and the subwoofer enclosure. - To install, tighten the bolt to 5 Nm (44 lb-in). 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8257 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 View 151-17 (Right Rear, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 8261 View 151-29 (Rear End) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 8262 Parking Assist Control Module: Diagrams C4014 C4226 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 8263 Parking Assist Control Module: Service and Repair PARKING AID MODULE Removal and Installation 1. Disconnect the parking aid module bumper harness from the body harness. 2. Remove the rear bumper cover. 3. Remove the 4 insulator-to-bumper cover nuts and the insulator from the bumper cover. 4. Disconnect the parking aid module bumper harness from the parking aid module. 5. Remove the 2 parking aid module bracket bolts. 6. Remove the parking module bracket assembly. 7. Release the module tabs from the bracket and remove the module. 8. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Pedal Positioning Module > Component Information > Description and Operation Pedal Positioning Module: Description and Operation Adjustable Pedals Using the adjustable pedal switch located on the instrument panel, the driver can adjust the brake and accelerator pedals for a more comfortable driving position. For removal and installation of the adjustable pedals, refer to Brake Pedal and Bracket. Adjustable Pedal Operation The adjustable pedals with or without memory feature are operational with the ignition switch in the ON or OFF position. The pedals are adjusted forward or rearward using the adjustable pedal switch. Memory Adjustable Pedal Operation The adjustable pedals with memory feature is controlled by using the memory switches or the remote keyless entry (RKE) transmitter. The exterior mirror and power driver seat positions are also stored and recalled with the power adjustable pedal positions. The system can store 3 memory settings. Driver Seat Module (DSM) The DSM controls the memory adjustable pedals. The DSM constantly monitors the systems under its control and records concerns in the form of diagnostic trouble codes (DTCs). A DTC can be retrieved with the scan tool through the data link connector (DLC). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations View 151-29 (Rear End) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left C4009 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 8273 C4011 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 8274 C4010 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 8275 C4012 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 8279 C2089 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Locations View 151-11 (behind Dash Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Locations > Page 8284 C239 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8289 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8290 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8291 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8292 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8293 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8294 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8295 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8296 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8297 Trailer Connector: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8298 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8299 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8300 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8301 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8302 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8303 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8304 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8305 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8306 Trailer Connector: Connector Views C439 C473 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8307 Trailer Connector: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 95-1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8308 95-2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8309 95-3 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. See: Diagrams/Components/Component Location Views Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair Trailer Hitch: Service and Repair Trailer Hitch Material Removal and Installation NOTE: The factory rear trailer hitch crossmember is welded to the frame. The service replacement trailer hitch crossmember will be bolted to the frame. All vehicles 1. Remove the spare tire. 2. Remove the rear bumper cover. 3. Disconnect the trailer wiring harness. Explorer/Mountaineer 4. Cut the rear rails vertically at least 10-18 mm (0.39-0.70 in) behind the rear body/box mount leg. - Use Explorer/Mountaineer template No. 1. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 8313 EXPLORER/MOUNTAINEER TEMPLATE # 1, LEFT HAND INNER SIDE VIEW, RIGHT HAND SYMMETRICALLY OPPOSITE 5. Drill 18 mm (0.688 in) diameter holes for the inboard and outboard attachments to each frame rail. - For the inboard side use Explorer/Mountaineer template No. 2. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 8314 EXPLORER/MOUNTAINEER TEMPLATE # 2, LEFT HAND INNER SIDE VIEW, RIGHT HAND INNER SYMMETRICALLY OPPOSITE TO LEFT HAND INNER - For the outboard side use Explorer/Mountaineer template No. 3. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 8315 EXPLORER/MOUNTAINEER TEMPLATE # 3, LEFT HAND OUTER SIDE VIEW, RIGHT HAND INNER SYMMETRICALLY OPPOSITE TO LEFT HAND INNER Explorer Sport Trac 6. Cut the rear rails vertically at least 10-18 mm (0.39-0.70 in) behind the rear body/box mount leg. - Use Sport Trac template No. 1. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 8316 SPORT TRAC TEMPLATE # 1, LEFT HAND INNER SIDE VIEW, RIGHT HAND SYMMETRICALLY OPPOSITE 7. Drill 18 mm (0.688 in) diameter holes for the inboard and outboard attachments to each frame rail. - Use Sport Trac Template No. 2. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 8317 SPORT TRAC TEMPLATE # 2, LEFT HAND INNER SIDE VIEW, RIGHT HAND INNER SYMMETRICALLY OPPOSITE TO LEFT HAND INNER - Use Sport Trac template No. 3. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 8318 SPORT TRAC TEMPLATE # 3, LEFT HAND OUTER SIDE VIEW, RIGHT HAND INNER SYMMETRICALLY OPPOSITE TO LEFT HAND INNER All vehicles 8. De-burr the cut edges of the frame rail and the drilled holes. 9. Clean the inner and outer surfaces of the frame rails, making sure all mating surfaces are free of foreign material. 10. Apply 3 even coats of the specified anti-corrosion coating onto the inner and outer surfaces of the frame rails where bare metal is present. 11. NOTE: It may be necessary to spread apart pull together the frame rails slightly to get brackets to fit. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 8319 Insert the new trailer hitch cross member assembly into the frame. 12. Hand start all 8 bolts into the weld nuts in the hitch brackets. 13. Tighten the inboard bolts. - Tighten to 235 Nm (174 lb-ft). 14. Tighten the outboard bolts. - Tighten to 235 Nm (174 lb-ft). 15. Install the trailer wiring harness. 16. Install the rear bumper cover. 17. Install the spare tire. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions Trailer Lamps: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8324 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8325 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8326 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8327 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8328 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8329 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8330 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8331 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8332 Trailer Lamps: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8333 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8334 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8335 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8336 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8337 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8338 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8339 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8340 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8341 Trailer Lamps: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 95-1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8342 95-2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8343 95-3 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. See: Diagrams/Components/Component Location Views Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 INSPECTION AND VERIFICATION 1. Verify the customer concern. 2. Verify the exterior lighting system of the vehicle is operating correctly. If not, refer to the appropriate pinpoint test. 3. Visually inspect the following for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical Battery junction box (BJB) fuse(s): 13 (30A) (trailer tow battery charge relay - switched) - 17 (30A) (trailer brake control module) - Smart junction box (SJB) fuse(s): 7 (15A) (trailer stop/turn lamps) - 12 (5A) (trailer tow battery charge relay coil) - 16 (10A) (trailer reversing lamps) - 25 (15A) (trailer parking lamps and trailer brake control module) - SJB - Circuity - Trailer 4. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. NOTE: - Make sure the headlamp switch is in the OFF position. - Make sure the multifunction switch is in the LOW BEAM position. 5. NOTE: Make sure to use the latest scan tool release software. If the cause is not visually evident, connect the scan tool to the data link connector (DLC). 6. NOTE: The vehicle communication module (VCM) LED prove-out confirms power and ground from the DLC are provided to the VCM. If the scan tool does not communicate with the VCM: Check the VCM connection to the vehicle. - Check the scan tool connection to the VCM. - Refer to Information Bus (Module Communications Network), No Power To The Scan Tool, to diagnose no communication with the scan tool. 7. If the scan tool does not communicate with the vehicle: - Verify the ignition key is in the ON position. - Verify the scan tool operation with a known good vehicle. - Refer to Information Bus (Module Communications Network) to diagnose no response from the powertrain control module (PCM). 8. Carry out the network test. - If the scan tool responds with no communication with the SJB, refer to Information Bus (Module Communications Network). - If the network test passes, retrieve and record the continuous memory DTCs. 9. Clear the continuous DTCs and carry out the self-test diagnostics for the SJB. 10. If the DTCs retrieved are related to the concern, go to the Smart Junction Box (SJB) Diagnostic Trouble Code (DTC) Chart. For all other DTCs, refer to Body Control Systems (Multifunction Electronic Control Module). See: Diagnostic Trouble Code Descriptions 11. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related Diagnostic Procedures NOTE: When diagnosing the trailer tow lamps, begin by verifying that the vehicle lamp systems are all functioning correctly with the trailer disconnected. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8346 B2070 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8347 Trailer Lamps: Symptom Related Diagnostic Procedures Symptom Chart (Part 1) Symptom Chart (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8348 Trailer Lamps: Pinpoint Tests Test V: The Trailer Lamps Are Inoperative - Trailer Parking Lamps PINPOINT TEST V: THE TRAILER LAMPS ARE INOPERATIVE - TRAILER PARKING LAMPS V1-V2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8349 V2-V3 Normal Operation Voltage to the trailer parking lamps is supplied by the smart junction box (SJB) through circuit CAT17 (BN). Possible Causes - Fuse - Circuit CAT17 (BN) open - Trailer - SJB Test W: The Trailer Lamps Are Inoperative - Trailer Reversing Lamps PINPOINT TEST W: THE TRAILER LAMPS ARE INOPERATIVE - TRAILER REVERSING LAMPS W1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8350 W1-W3 Normal Operation Voltage to the trailer reversing lamps is supplied by the smart junction box (SJB) through circuit CAT16 (GY/BN). Possible Causes - Fuse - Circuit CAT16 (GY/BN) open - Trailer - SJB Test X: The Individual Trailer Lamp Is Inoperative - LH Trailer Stoplamp PINPOINT TEST X: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - LH TRAILER STOPLAMP Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8351 X1-X2 X3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8352 Normal Operation Voltage to the LH trailer stoplamp is supplied by the smart junction box (SJB) through circuit CAT06 (YE). DTC B2070 - is a continuous DTC that sets when the SJB detects a short to ground from the LH trailer turn/stoplamp voltage supply circuit. The self-test must be run after the repair in order for the SJB to enable the output for the LH trailer turn/stoplamp voltage supply. Possible Causes - Circuit CAT06 (YE) open or short to ground - Trailer - SJB Test Y: The Individual Trailer Lamp Is Inoperative - RH Trailer Stoplamp PINPOINT TEST Y: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - RH TRAILER STOPLAMP Y1-Y2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8353 Y2-Y3 Normal Operation Voltage to the RH trailer stoplamp is supplied by the smart junction box (SJB) through circuit CAT09 (GN). DTC B2070 - is a continuous DTC that sets when the SJB detects a short to ground from the RH trailer turn/stoplamp voltage supply circuit. The self-test must be run after the repair in order for the SJB to enable the output for the RH trailer turn/stoplamp voltage supply. Possible Causes - Circuit CAT09 (GN) open or short to ground - Trailer - SJB Test Z: The Trailer Lamps Are On Continuously PINPOINT TEST Z: THE TRAILER LAMPS ARE ON CONTINUOUSLY Z1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8354 Z1-Z3 Normal Operation Voltage to the trailer tow lamps is controlled by the smart junction box (SJB). Circuits CAT06 (YE) and CAT09 (GN) supply voltage to the trailer tow LH and RH stoplamps, respectively. Possible Causes - Circuit CAT06 (YE) short to voltage - Circuit CAT09 (GN) short to voltage - Trailer - SJB Tests AA: The Trailer Battery Charging Is Inoperative/Does Not Operate Correctly PINPOINT TEST AA: THE TRAILER BATTERY CHARGING IS INOPERATIVE/DOES NOT OPERATE CORRECTLY Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8355 AA1-AA3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8356 AA3-AA4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8357 AA4-AA5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8358 AA5 Continued Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8359 AA6-AA8 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8360 AA8-AA10 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8361 AA10-AA11 Normal Operation The trailer battery charge relay coil receives voltage from the smart junction box (SJB) fuse 12 (5A) through circuit CBP12 (GN/WH) when the ignition switch is in the RUN or ACC position. Ground for the trailer battery charge relay coil is supplied through circuit GD120 (BK/GN). The battery junction box (BJB) fuse 13 (30A) supplies voltage to the trailer battery charge relay through circuit SSB13 (GY/RD). When the trailer battery charge relay is energized, the voltage is routed to the trailer tow connector through circuit CAT14 (OG). Possible Causes - Fuse - Circuit CAT14 (OG) open or short to voltage - Circuit CBP12 (GN/WH) open or short to voltage - Circuit GD120 (BK/GN) open - Circuit SSB13 (GY/RD) open - Trailer battery charge relay - Trailer - SJB Tests AB: The Trailer Electric Brakes Are Inoperative/Do Not Operate Correctly PINPOINT TEST AB: THE TRAILER ELECTRIC BRAKES ARE INOPERATIVE/DO NOT OPERATE CORRECTLY Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8362 AB1-AB2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8363 AB3-AB5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8364 AB6-AB8 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8365 AB9 Normal Operation The trailer electric brake controller is provided voltage at all times by the battery junction box (BJB) fuse 17 (30A) through circuit SBB17 (RD). Ground for the trailer electric brake controller is provided through circuit GD138 (BK/WH). The trailer electric brake controller receives voltage from the stoplamp switch through circuit CCB08 (VT/WH) when the brake pedal is applied. When requested, the trailer electric brake controller provides voltage to the trailer tow connector through circuit CAT19 (BU). Possible Causes - Fuse - Circuit CAT17 (BN) open - Circuit CAT19 (BU) open, short to ground, or short to voltage - Circuit CCB08 (VT/WH) open - Circuit GD138 (BK/WH) open - Circuit SBB17 (RD) open - Trailer electric brake controller - Trailer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Page 8366 Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Page 8370 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Locations > Page 8374 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8379 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8380 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8381 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8382 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8383 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8384 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8385 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8386 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8387 Trailer Connector: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8388 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8389 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8390 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8391 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8392 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8393 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8394 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8395 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8396 Trailer Connector: Connector Views C439 C473 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8397 Trailer Connector: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 95-1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8398 95-2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8399 95-3 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. See: Diagrams/Components/Component Location Views Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Specifications Torque Specifications Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) Body Control Module: Service and Repair Driver Seat Module (DSM) DRIVER SEAT MODULE (DSM) Special Tool(s) Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 8407 Removal and Installation CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: Prior to the removal of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new DSM after installation. 1. Remove the driver seat. 2. Remove the 2 DSM screws. 3. Disconnect the electrical connectors and remove the DSM. 4. NOTE: Once the module is installed it is necessary to download the module configuration information from the scan tool into the new module. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 8408 Body Control Module: Service and Repair Smart Junction Box (Sjb) SMART JUNCTION BOX (SJB) Special Tool(s) Special Tool(s) Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 8409 Part 2 Removal NOTE: - The steps included in the SJB removal and installation procedure are critical to restoring the vehicle security and tire pressure monitoring systems to normal operation. A new SJB is delivered in manufacturing mode with 6 pre-set diagnostic trouble codes (DTCs) related to the tire pressure monitoring system. The presence of these DTCs requires the installation procedures be followed in order to clear the DTCs and enable normal SJB operations. - Prior to the removal of the SJB, it is necessary to upload the module configuration information to the diagnostic tool. This information must be downloaded to the new SJB after installation. 1. Remove the driver door scuff plate. 2. Position the LH door opening weather seal aside. 3. NOTE: While pulling the trim panel rearward, pull the hood release lever rearward in order for the release lever to slide through the trim panel. Remove the pushpin and the cowl side trim panel. 4. Remove the 2 bolts and the parking brake release handle. 5. Disconnect the parking brake switch electrical connector. 6. Release the hood release cable pushpin from the parking brake control bracket. 7. Release the harness clip from the parking brake cable housing. 8. NOTE: Rotating the parking brake control counterclockwise allows enough access to clear the instrument panel reinforcement. Remove the 3 bolts and position the parking brake control assembly under the brake pedal. 9. CAUTION: The lower side of the headlight switch bezel includes 2 tabs that slide down onto the instrument panel and may be broken if any prying force is exerted in the lower area of the bezel. Using a suitable tool, pry the mid-to-upper side of the headlight switch bezel away from the instrument panel, disconnect the 2 electrical connectors and position the bezel assembly aside. 10. If necessary, push the LH instrument panel side finish panel out and position it aside. 11. Through the headlight switch bezel opening, remove the 2 SJB bolts. 12. From under the instrument panel, remove the third SJB bolt. 13. NOTE: The SJB electrical connector levers must click into a fully released position before they can be removed and must click into a fully closed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) > Page 8410 (connected) position when installing. Pull the SJB down out of the 2 locating pins, disconnect the 5 electrical connectors and remove the SJB. Installation NOTE: When a new SJB is installed, all customer RKE transmitters may be required to program the RKE transmitters to the new SJB. 1. NOTE: The SJB electrical connector levers must click into a fully released position before they can be removed and must click into a fully closed (connected) position when installing. Position the SJB into the 2 locating pins and connect the 5 electrical connectors. 2. From under the instrument panel, install the SJB bolt. 3. Through the headlight switch bezel opening, install the 2 SJB bolts. 4. If necessary, install the LH instrument panel side finish panel. 5. Connect the 2 electrical connectors and install the headlight switch bezel assembly into the instrument panel. 6. Position the parking brake control assembly and install the 3 bolts. - Tighten to 20 Nm (15 lb-ft). 7. Install the harness clip on the parking brake cable housing. 8. Install the hood release cable pushpin into the parking brake control bracket. 9. Connect the parking brake switch electrical connector. 10. Position the parking brake release handle and install the 2 bolts. 11. Position the hood release lever assembly and install the bolt. 12. NOTE: While installing the trim panel, pull the hood release lever rearward in order for the release lever to slide through the trim panel. Position the cowl side trim panel and install the pushpin. 13. Position the LH door opening weather seal. 14. Install the driver door scuff plate. 15. NOTE: When successful, this step provides the calibration necessary for SJB operation and clears DTC B2477. The clearing of the DTC indicates the calibration data has been successfully downloaded to the SJB. Download the SJB configuration information from the diagnostic tool to the SJB. 16. NOTE: When successful, this step clears DTCs B2868, B2869, B2870 and B2871. The clearing of these DTCs indicates the SJB has recognized the tire pressure sensors during the training procedure. Train the tire pressure sensors. 17. Clear the DTCs. 18. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode, and to be sure there are no other concerns with the newly programmed SJB. Carry out the SJB on-demand self-test. 19. NOTE: If the module configuration upload/download is successful, then the RKE transmitters do not need to be reprogrammed to the vehicle. However, if the module configuration upload/download is unsuccessful and as-built data must be used to configure the module, then ALL of the customer's RKE transmitters must be reprogrammed to the vehicle. Program the RKE transmitters to the new SJB (if necessary). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Module > Component Information > Service and Repair Auxiliary Step / Running Board Module: Service and Repair RETRACTABLE RUNNING BOARD MODULE Removal and Installation 1. Remove the RH C-pillar trim panel. 2. Disconnect the retractable running board module electrical connectors. 3. Remove the 3 screws and the retractable running board module assembly. - To install, tighten to 7 Nm (62 lb-in). 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor > Component Information > Locations > Running Board Motor, Left View 151-15 (Left Rear, (1 0f 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor > Component Information > Locations > Running Board Motor, Left > Page 8419 View 151-18 (Right Rear, (2 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor > Component Information > Diagrams > Running Board Motor, Left C3185 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor > Component Information > Diagrams > Running Board Motor, Left > Page 8422 C3186 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor > Component Information > Diagrams > Page 8423 Auxiliary Step / Running Board Motor: Service and Repair RETRACTABLE RUNNING BOARD MOTOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: If the retractable running board cannot be extracted, extend the running board by hand. Extend the retractable running board. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor > Component Information > Diagrams > Page 8424 3. Remove the straps and disconnect the retractable running board motor electrical connector. 4. Remove the wedge screw and wedge. Note orientation for reinstallation. - To install, tighten to 8 Nm (71 lb-in). 5. Remove the 3 bolts and retractable running board motor. 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Procedures Front Bumper Cover / Fascia: Procedures TAB REPAIR - BUMPER 1. NOTE: - Inspect the bumper cover to determine if part can be repaired to an acceptable level of quality of appearance, fit and durability. Will labor and material cost of the repair meet or exceed the cost of a new replacement bumper cover. If the bumper cover is determined to be repairable, proceed to the following steps. - The following steps are to be used as a guideline. Depending on what brand of adhesives, patch material etc., are used, procedures may vary slightly. Remove the affected bumper. 2. Clean the broken tab(s) with a plastics wax and grease remover. 3. Hand sand the repair area with 80-grit sandpaper and remove any foreign material with compressed air. 4. Apply a plastics adhesion promoter per label directions to the repair area. 5. Measure and cut a patch of fiberglass cloth or equivalent large enough to form the front of the tab, then slope back in a wedge shape approximately 51 mm (2 in) from original tab. 6. Prepare the repair adhesive per manufacturer's instructions and apply to the affected area. - Immediately apply the plastic repair material to form the tab shape. 7. Allow appropriate cure time and shape the repair tab using a small angle sander. Use extreme care to not sand through the exterior surface. 8. Perform any required paint repair operations to the bumper cover using Ford-approved paint systems. 9. Reassemble and install the bumper cover. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Procedures > Page 8431 Front Bumper Cover / Fascia: Removal and Replacement FRONT BUMPER COVER Explorer/Explorer Sport Trac Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Procedures > Page 8432 Mountaineer Exploded Views Removal and Installation Explorer 1. Remove the headlamp assemblies. All vehicles 2. Disconnect the fog lamp electrical connectors, if equipped. 3. Disconnect the side turn signal lamp electrical connectors, if equipped. 4. Remove the front fender inner splash shield screws. 5. Remove the front fender inner splash shield pin-type retainers. 6. Remove the front fender inner splash shields. 7. Remove the 2 bolts from the bottom of the bumper cover. Explorer 8. Remove the 6 grille-to-grille opening panel scrivets. NOTE: The fender clips are removed with the front fender. Use a flat-blade screwdriver to release the locking tabs from the front bumper cover. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Procedures > Page 8433 9. Release the bumper cover-to-fender clips. Mountaineer 10. Remove the bumper cover upper screws. 11. Rotate the bottom of the front bumper cover upward. 12. Apply downward pressure to the top of the front bumper cover to release the 3 locking tabs. All vehicles 13. Remove the front bumper cover. 14. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair Front Bumper Reinforcement: Service and Repair Bumper - Front Explorer/Explorer Sport Trac Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair > Page 8437 Mountaineer Exploded Views Removal and Installation 1. Remove the front bumper cover. 2. Remove the 4 front bumper bolts. - To install, tighten to 48 Nm (35 lb-ft). 3. Remove the front bumper. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Procedures Rear Bumper Cover / Fascia: Procedures TAB REPAIR - BUMPER 1. NOTE: - Inspect the bumper cover to determine if part can be repaired to an acceptable level of quality of appearance, fit and durability. Will labor and material cost of the repair meet or exceed the cost of a new replacement bumper cover. If the bumper cover is determined to be repairable, proceed to the following steps. - The following steps are to be used as a guideline. Depending on what brand of adhesives, patch material etc., are used, procedures may vary slightly. Remove the affected bumper. 2. Clean the broken tab(s) with a plastics wax and grease remover. 3. Hand sand the repair area with 80-grit sandpaper and remove any foreign material with compressed air. 4. Apply a plastics adhesion promoter per label directions to the repair area. 5. Measure and cut a patch of fiberglass cloth or equivalent large enough to form the front of the tab, then slope back in a wedge shape approximately 51 mm (2 in) from original tab. 6. Prepare the repair adhesive per manufacturer's instructions and apply to the affected area. - Immediately apply the plastic repair material to form the tab shape. 7. Allow appropriate cure time and shape the repair tab using a small angle sander. Use extreme care to not sand through the exterior surface. 8. Perform any required paint repair operations to the bumper cover using Ford-approved paint systems. 9. Reassemble and install the bumper cover. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Procedures > Page 8443 Rear Bumper Cover / Fascia: Removal and Replacement BUMPER COVER - REAR, EXPLORER Explorer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Procedures > Page 8444 Mountaineer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Procedures > Page 8445 Explorer Sport Trac Exploded View Removal and Installation 1. Remove the tail lamp assemblies. 2. Remove the 2 rear bumper cover bracket bolts. - To install, tighten to 11 Nm (8 lb-ft). 3. Remove the 9 bumper cover pin-type retainers. 4. Remove the 2 rear bumper bracket bolts. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Procedures > Page 8446 5. Disconnect the rear parking aid sensor electrical connector, if equipped. 6. CAUTION: To avoid damaging the rear bumper cover, do not twist the cover when removing. Remove the bumper cover. Lift the outer corners upward and pull the bumper cover straight up and out. 7. Transfer components as necessary. 8. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL PANEL GRILLE 1. Remove the wiper pivot arms. CAUTION: To avoid breaking the retaining clips on the cowl panel, do not pull up on the rear of the cowl panel. 2. Pry up on the front of the cowl panel to release it from the retaining clips. 3. Remove the cowl panel grille. 4. Separate the left cowl panel from the right cowl panel by releasing the retaining clips. 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 EXTERIOR FRONT DOOR HANDLE Removal and Installation 1. Remove the front door trim panel. 2. Position the watershield aside. 3. Remove the screw and the energy absorbing foam pad. 4. If equipped, disconnect the door lock cylinder actuating rod. 5. Open the clip and disconnect the exterior front door handle actuating rod. 6. Remove the 2 exterior front door handle nuts. - To install, tighten to 9 Nm (80 lb-in). 7. Remove the exterior front door handle. 8. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 INTERIOR DOOR HANDLE - FRONT Removal and Installation 1. Remove the front door trim panel. 2. Remove the 3 screws and the interior front door handle. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair Front Door Latch: Service and Repair FRONT DOOR LATCH Removal and Installation 1. Remove the front door trim panel. 2. Position the watershield aside. 3. NOTE: Slide the foam insulating block forward to release the 2 clips. Remove the screw and the energy absorbing foam pad. 4. Release the interior door handle actuating cable locator from the door frame. 5. Disconnect the front door latch harness electrical connector and release the harness locator from the door frame. 6. Open the clip and disconnect the exterior front door handle actuating rod. 7. Release the front door push button rod from the door frame retainer. 8. If equipped, disconnect the front door lock cylinder actuating rod from the lock cylinder. 9. Remove the 3 screws and the front door latch. - To install, tighten to 12 Nm (9 lb-ft). 10. To install, reverse the removal procedure. - Lubricate the front door latch after installation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 DOOR TRIM PANEL - FRONT Removal and Installation 1. Remove the front door trim panel assist handle cover. 2. Remove the front door trim panel assist handle screws. 3. Remove the front door trim panel handle bezel cover. 4. Remove the front door trim panel handle bezel screws. 5. Remove the front door trim panel lower screws. CAUTION: To avoid damaging the front door trim panel, do not pull the bottom of the panel outward. 6. Remove the front door trim panel by lifting upward on the armrest to disengage the panel clips. 7. Disconnect the electrical connectors. 8. Disconnect the lock rod cable from the front door trim panel. 9. Disconnect the door handle conduit and cable from the front door trim panel. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Page 8467 10. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Adjustments Front Door Striker: Adjustments STRIKER ADJUSTMENT 1. Loosen the door latch striker plate bolts. 2. Adjust the door latch striker plate from side-to-side or up and down as necessary. 3. Tighten the door latch striker plate bolts. - Tighten to 30 Nm (22 lb-ft). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair Front Door Window Glass Weatherstrip: Service and Repair DOOR GLASS TOP RUN - FRONT Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Page 8475 Part 2 Exploded Views Removal and Installation 1. Remove the front door window glass. 2. Remove the exterior moulding. 3. Remove the front door glass top run channel assembly bolt. - To install, tighten to 12 Nm (9 lb-ft). 4. Remove the front door glass top run channel assembly through the top opening of the front door. 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair WINDOW REGULATOR MOTOR - FRONT DOOR Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair > Page 8479 Part 2 Exploded View Removal and Installation 1. Remove the front door window regulator. 2. Remove the 3 front door window regulator motor bolts. - To install, tighten to 7 Nm (62 lb-in). 3. Remove the front door window regulator motor. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair Front Door Window Regulator: Service and Repair WINDOW REGULATOR - FRONT DOOR Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Page 8483 Part 2 Exploded View Removal and Installation 1. Remove the front door trim panel. 2. Remove the front door speaker. 3. Remove the exterior mirror front door weather shield. 4. Disconnect the exterior mirror electrical connector. 5. Release the 3 door wiring harness pin-type retainers. 6. Remove the front door weather shield. 7. Remove the door trim panel reinforcement screw. 8. Remove the door trim panel reinforcement. 9. CAUTION: Make sure the holes in the glass bracket do not become enlarged during the rivet removal process. If the holes become enlarged, the new rivets may become loose, resulting in a clicking noise concern. NOTE: Use a 4.5 mm (0.1772 in) drill bit to drill out the glass-to-regulator rivets. Remove the 2 front door window glass-to-regulator rivets. Position the front door window glass as necessary to access the front door window glass-to-regulator rivets. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Page 8484 10. Secure the front door glass in the full up position with tape. 11. Disconnect the window regulator motor electrical connector. 12. Remove the 5 window regulator assembly nuts. - To install, tighten to 10 Nm (89 lb-in). 13. Remove the window regulator assembly. 14. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 EXTERIOR REAR DOOR HANDLE Removal and Installation 1. Remove the rear door trim panel. 2. Position the watershield aside. 3. Open the clip and disconnect the exterior rear door handle actuating rod. 4. Remove the 2 nuts and the exterior rear door handle. - To install, tighten to 9 Nm (80 lb-in). 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 INTERIOR DOOR HANDLE - REAR Removal and Installation 1. Remove the rear door trim panel. 2. Remove the 3 interior rear door handle screws and the interior rear door handle. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair Rear Door Latch: Service and Repair REAR DOOR LATCH Removal and Installation 1. Remove the rear door trim panel. 2. Position the watershield aside. 3. Release the interior door handle actuating cable locator from the door frame. 4. Open the clip and disconnect the exterior handle actuating rod. 5. Disconnect the rear door ajar switch and rear door lock actuator electrical connectors. 6. Remove the 3 rear door latch screws. - To install, tighten to 12 Nm (9 lb-ft). 7. Release the rear door push button rod from the door frame retainer. 8. To install, reverse the removal procedure. - Lubricate the door latch after installation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 DOOR TRIM PANEL - REAR Explorer/Mountaineer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Page 8499 Explorer Sport Trac Removal and Installation 1. Remove the rear door trim panel assist handle cover. 2. Remove the rear door trim panel assist handle screws. 3. Remove the rear door trim panel handle bezel cover. 4. Remove the rear door trim panel handle bezel screws. 5. Remove the rear door trim panel lower screw. 6. CAUTION: To avoid damaging the trim panel, do not pull the bottom of the panel outward. Remove the rear door trim panel by lifting upward on the armrest to disengage the panel clips. 7. Disconnect the electrical connectors. 8. Disconnect the rod cable from the rear door trim panel. 9. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Adjustments Rear Door Striker: Adjustments STRIKER ADJUSTMENT 1. Loosen the door latch striker plate bolts. 2. Adjust the door latch striker plate from side-to-side or up and down as necessary. 3. Tighten the door latch striker plate bolts. - Tighten to 30 Nm (22 lb-ft). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair Rear Door Window Glass Weatherstrip: Service and Repair DOOR GLASS TOP RUN - REAR Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Page 8507 Part 2 Exploded View Removal and Installation 1. Remove the rear door window glass. 2. Remove the exterior moulding. 3. Remove the rear door glass top run assembly bolt. - To install, tighten to 12 Nm (9 lb-ft). 4. Remove the rear door glass top run channel assembly. - Remove the rear door glass top run channel assembly through the top opening of the rear door. 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair Rear Door Window Motor: Service and Repair WINDOW REGULATOR MOTOR - REAR DOOR Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair > Page 8511 Part 2 Exploded View Removal and Installation 1. Remove the interior moulding. 2. Remove the rear door trim panel and weather shield. 3. Remove the 3 window regulator motor bolts. - To install, tighten to 7 Nm (62 lb-in). 4. Remove the window regulator motor. 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair Rear Door Window Regulator: Service and Repair WINDOW REGULATOR - REAR DOOR Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Page 8515 Part 2 Exploded View Removal and Installation 1. Remove the rear door trim panel. 2. Remove the rear door speaker. 3. Remove the interior moulding. 4. Remove the rear door weather shield. 5. CAUTION: Make sure the hole in the glass bracket does not become enlarged during the rivet removal process. If the hole becomes enlarged, the new rivet may become loose, resulting in a clicking noise concern. NOTE: Use a 4.5 mm (0.1772 in) drill bit to drill out the glass-to-regulator rivets. Remove the rear door window glass-to-regulator rivet. Position the rear door window glass as necessary to access the rear door window glass-to-regulator rivet. 6. Secure the rear door window glass in the full up position with tape. 7. Disconnect the window regulator motor electrical connector. 8. Remove the 2 window regulator nuts. - To install, tighten to 10 Nm (89 lb-in). 9. Remove the 3 window regulator motor bracket nuts. - To install, tighten to 10 Nm (89 lb-in). 10. Remove the window regulator assembly. 11. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair Hood Latch: Service and Repair HOOD LATCH Removal and Installation NOTE: Mark the position of the hood latch prior to removing the hood latch bolts to aid positioning during installation. 1. Remove the 2 hood latch bolts. - To install, tighten to 12 Nm (9 lb-ft). 2. Disconnect the hood latch release cable from the hood latch and remove the latch. 3. To install, reverse the removal procedure. - Check the latch adjustment to make sure the latch was installed and aligned correctly. - Lubricate the hood latch after installation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release > Component Information > Service and Repair Hood Latch Release: Service and Repair HOOD LATCH RELEASE HANDLE Removal and Installation 1. Remove the hood latch. 2. Remove the screw and the hood latch release handle. 3. Remove the pin-type retainer and the LH A-pillar lower trim panel. 4. Remove the hood latch release cable assembly screw. 5. Release the hood latch release cable from the 4 cable locators and remove the cable. 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 WINDOW GLASS - LIFTGATE Material Material Removal and Installation 1. If installing a new liftgate window glass, remove the rear window wiper motor. 2. Position the liftgate trim panel aside to access the liftgate window glass electrical connectors and the 2 liftgate window glass hinge-to-glass screws. 3. Disconnect the liftgate window glass electrical connectors. 4. CAUTION: Open and support the liftgate window glass before removing the liftgate window glass struts. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Page 8527 Remove the liftgate window glass struts. To avoid breaking the liftgate window glass, disconnect the liftgate window glass struts from the liftgate window glass before disconnecting the liftgate window glass struts from the rear liftgate. 5. Remove the 2 liftgate hinge-to-glass screws. - Apply threadlock into the liftgate window glass hinge-to-glass bolt hole, making sure that the threadlock is on the threads. - To install, tighten to 10 Nm (89 lb-in). 6. With the help of an assistant, remove the liftgate window glass. 7. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Liftgate Glass Actuator View 151-25 (Liftgate) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Liftgate Glass Actuator > Page 8532 View 151-25 (Liftgate) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Diagrams > Liftgate Glass Actuator C4040 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Diagrams > Liftgate Glass Actuator > Page 8535 C457 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Service and Repair > Liftgate Latch Actuator Power Trunk / Liftgate Lock Actuator: Service and Repair Liftgate Latch Actuator LIFTGATE LATCH ACTUATOR Removal and Installation 1. Remove the liftgate latch. 2. Release the locking tab and remove the liftgate latch actuator. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Service and Repair > Liftgate Latch Actuator > Page 8538 Power Trunk / Liftgate Lock Actuator: Service and Repair Liftgate Window Latch Actuator LIFTGATE WINDOW LATCH ACTUATOR Removal and Installation 1. Remove the liftgate window latch. 2. Remove the 3 screws and the liftgate window latch actuator. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Locations View 151-25 (Liftgate) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Page 8542 C4039 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Service and Repair Trunk / Liftgate Handle: Service and Repair LIFTGATE RELEASE HANDLE Removal and Installation 1. Remove the liftgate trim panel. 2. Position the watershield aside. 3. Disconnect the liftgate release handle actuating rod. 4. Remove the 2 liftgate release handle screws. 5. Remove the liftgate release handle. 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim Panel > Component Information > Service and Repair Trunk / Liftgate Interior Trim Panel: Service and Repair LIFTGATE TRIM PANEL Removal and Installation 1. Remove the 2 liftgate grab handle screws. 2. Remove the liftgate grab handle. 3. CAUTION: To avoid damaging the trim panel, do not pull the bottom of the panel outward. Lift the liftgate trim panel by lifting upward to disengage the clips and remove the panel. Disconnect the liftgate trim panel electrical connector. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 LIFTGATE LATCH Removal and Installation 1. Remove the liftgate trim panel. 2. Position the watershield aside. 3. Disconnect the liftgate release handle actuating rod. 4. Disconnect the liftgate latch actuator and the liftgate ajar switch electrical connectors. 5. Remove the 3 liftgate latch screws and remove the latch. - To install, tighten to 12 Nm (9 lb-ft). 6. To install, reverse the removal procedure. - Lubricate the liftgate latch after installation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 8553 Trunk / Liftgate Latch: Service and Repair Liftgate Window Latch LIFTGATE WINDOW LATCH Removal and Installation 1. Remove the liftgate trim panel. 2. Position the watershield aside. 3. Disconnect the liftgate window actuator and liftgate window ajar switch electrical connectors. 4. Remove the 4 screws and the liftgate window latch. - To install, tighten to 12 Nm (9 lb-ft). 5. To install, reverse the removal procedure. - Lubricate the liftgate window latch after installation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair TAILGATE LOCK CYLINDER Removal and Installation NOTE: - When a new lock cylinder is installed, the tailgate lock cylinder, door lock cylinders and the ignition lock cylinder should be installed as a set. This eliminates carrying an extra key which fits only 1 lock. If a new key is to be used, the new key code is attached to a tag. - The individual door lock cylinders are repaired by discarding the inoperative lock cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build a new lock cylinder to the current key code of the vehicle. 1. Remove the tailgate release handle. 2. Remove retaining clip and the tailgate lock cylinder. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1. Remove the wiper pivot arms. CAUTION: To avoid breaking the retaining clips on the cowl panel, do not pull up on the rear of the cowl panel. 2. Pry up on the front of the cowl panel to release it from the retaining clips. 3. Remove the cowl panel grille. 4. Separate the left cowl panel from the right cowl panel by releasing the retaining clips. 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Explorer/Explorer Sport Trac Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Page 8566 Mountaineer Exploded View Removal and Installation 1. Loosen the running board bolts and lower the running board to access the front fender moulding pin-type retainer. - To install, tighten to 23 Nm (17 lb-ft). 2. Remove the lower pin-type retainer from the front fender moulding. 3. Remove the 2 rear pin-type retainers from the front fender moulding. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Page 8567 4. Position the front fender moulding aside and remove the splash shield lower screw. 5. Remove the front splash shield screws. 6. Remove the front splash shield pin-type retainers. 7. Remove the front splash shield. 8. Remove the front fender splash shield. 9. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Fender > Rear Fender > Rear Fender Liner > System Information > Service and Repair Rear Fender Liner: Service and Repair PICKUP BED WHEEL HOUSE Removal and Installation RH and LH 1. Remove the rear fender moulding. 2. NOTE: LH shown, RH similar. Remove the 3 bumper cover screws. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Fender > Rear Fender > Rear Fender Liner > System Information > Service and Repair > Page 8572 3. NOTE: RH shown, LH similar. Remove the 4 rear wheel house-to-wheel house opening screws. RH only 4. Remove the pin-type retainer. RH and LH 5. NOTE: RH shown, LH similar. Remove the rear wheel house. Remove the screws. - Remove the rear wheel house. 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Explorer / Mountaineer Body / Frame Mount Bushing: Description and Operation Explorer / Mountaineer FRAME AND BODY MOUNTING The frame consists of 2 steel channel rails, 9 crossmembers for Explorer Sport Trac or 8 crossmembers for Explorer/Mountaineer including a front crossmember, transmission support crossmember and a rear crossmember (trailer hitch). New side rails and welded crossmembers, including the trailer hitch, are not installed separately. A front frame rail repair kit is available if the front rail is to be repaired and a rear crossmember (hitch) repair kit is available if the rear crossmember or rail is to be repaired. The 1B crossmember and transmission crossmember are included in assembly to the frame but can be serviced separately. Frame-Mounted Heat Shields Structural Enhancement - Explorer/Mountaineer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Explorer / Mountaineer > Page 8578 Structural Enhancement - Explorer Sport Trac The frame-mounted heat shields are attached to the top of the frame and crossmembers with bolts. The body must be lifted off the frame enough for access to the bolts that attach the heat shields to the top of the frame. The purpose of these inserts is to enhance the structural rigidity of the frame in this area. The inserts cannot be replaced or repaired. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Explorer / Mountaineer > Page 8579 Body / Frame Mount Bushing: Description and Operation Frame and Body Mounting Frame and Body Mounting The frame consists of 2 steel channel rails, 9 crossmembers for Explorer Sport Trac or 8 crossmembers for Explorer/Mountaineer including a front crossmember, transmission support crossmember and a rear crossmember (trailer hitch). New side rails and welded crossmembers, including the trailer hitch, are not installed separately. A front frame rail repair kit is available if the front rail is to be repaired and a rear crossmember (hitch) repair kit is available if the rear crossmember or rail is to be repaired. The 1B crossmember and transmission crossmember are included in assembly to the frame but can be serviced separately. Frame-Mounted Heat Shields The frame-mounted heat shields are attached to the top of the frame and crossmembers with bolts. The body must be lifted off the frame enough for access to the bolts that attach the heat shields to the top of the frame. Structural Enhancement - Explorer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Explorer / Mountaineer > Page 8580 Structural Enhancement - Explorer Sport Trac The purpose of these inserts is to enhance the structural rigidity of the frame in this area. The inserts cannot be replaced or repaired. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 Body Support - Number 1 Removal and Installation CAUTION: When removing upper body mounts, all other body mount support bolts must be loose before raising the vehicle body from the frame, to prevent damage occurring to the vehicle. NOTE: - Body mounts must be held with a wrench on the bottom while loosening the bolt from the top. - 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 mount support installation. 1. Remove the scuff plate trim panels. 2. Remove the cowl side trim panels. 3. Position the carpeting aside and remove the body insulator plug button. 4. Remove the body support bolt. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 8583 - To install, tighten to 90 Nm (66 lb-ft). 5. Remove the body support washer. 6. Remove the body support nuts. - To install, tighten to 103 Nm (76 lb-ft). 7. Remove the upper body mount. 8. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 8584 Body / Frame Mount Bushing: Service and Repair Body Support - Number 2 Body Support - Number 2 Body Support - Number 2 Removal and Installation CAUTION: When removing upper body mounts, enough adjacent body mount support bolts or nuts must be removed to prevent damage occurring to the vehicle. NOTE: - Body mounts must be held with a wrench on the bottom while loosening the bolt from the top. - 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 mount support installation. 1. Remove front seat. 2. Remove the B-pillar trim panel. 3. Position the carpet aside and remove the body insulator plug button. 4. Remove the body support bolt. - To install, tighten to 90 Nm (66 lb-ft). 5. Remove the body support washer. 6. Remove the lower body support mount. 7. Remove enough adjacent body mount bolts to allow for the removal of the upper half of the mount without damaging the vehicle. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 8585 8. Carefully raise the vehicle body enough to remove the upper body mount. 9. Remove the upper body mount. 10. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 8586 Body / Frame Mount Bushing: Service and Repair Body Support - Number 3 Body Support - Number 3 Body Support - Number 3 (Explorer/Mountaineer) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 8587 Body Support - Number 3 (Explorer Sport Trac) CAUTION: When removing upper body mounts, enough adjacent body mount support bolts and nuts must removed to prevent damage occurring to the vehicle. NOTE: - Body mounts must be held with a wrench on the bottom while loosening the bolt from the top. - 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 mount support installation. Explorer and Mountaineer only 1. Remove the rear seat. 2. Remove the B-pillar trim panel. Explorer Sport Trac only 3. Remove the scuff plate trim panels. 4. Remove the cowl side trim panels. All vehicles 5. Position the carpet aside and remove the body insulator plug button. 6. Remove the body support bolt. - To install, tighten to 90 Nm (66 lb-ft). 7. Remove the body support washer. Explorer and Mountaineer only Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 8588 8. Remove the lower body support mount. Explorer Sport Trac only 9. Remove enough adjacent body mount bolts to allow for the removal of the upper half of the mount without damaging the vehicle. All vehicles 10. Carefully raise the vehicle body enough to remove the upper body mount. Explorer Sport Trac only 11. Remove the body support nuts and remove the lower body mount. - To install, tighten to 103 Nm (76 lb-ft). All vehicles 12. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 8589 Body / Frame Mount Bushing: Service and Repair Body Support - Number 4 Body Support - Number 4 Body Support - Number 4 Removal and Installation CAUTION: When removing upper body mounts, enough adjacent body mount support bolts or nuts must be removed to prevent damage occurring to the vehicle. NOTE: - Body mounts must be held with a wrench on the bottom while loosening the bolt from the top. - 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 mount support installation. 1. Position the rear storage compartment trim cover open and remove the body insulator plug button. 2. Remove the body support bolt. - To install, tighten to 90 Nm (66 lb-ft). 3. Remove the body support washer. 4. Remove the lower body support mount. 5. Remove enough adjacent body mount bolts to allow for the removal of the upper part of the mount without damaging the vehicle. 6. Carefully raise the vehicle body enough to remove the upper body mount. 7. Remove the upper body mount. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 8590 8. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 8591 Body / Frame Mount Bushing: Service and Repair Body Support - Front End Sheet Metal Body Support - Front End Sheet Metal Body Support Front End Sheet Metal Removal and Installation CAUTION: When removing the front upper body mounts, enough adjacent body mount support bolts or nuts must be removed to prevent damage occurring to the vehicle. 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 mount support installation. 1. Remove the body support nut. - To install, tighten to 55 Nm (41 lb-ft). 2. Remove the body support washer. 3. Remove the body support bolt. - To install, tighten to 55 Nm (41 lb-ft). 4. Remove the front end sheet metal body support lower mount. 5. NOTE: Body mounts must be held with a wrench on the bottom while loosening the nuts from the top. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 8592 Remove enough adjacent body mount bolts to allow for the removal of the upper half of the mount without damaging the vehicle. 6. Carefully raise the vehicle body enough to remove the front end sheet metal body support upper mount. 7. Remove the front end sheet metal body support upper mount. 8. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Crossmember - 1B Rear Cross-Member: Service and Repair Crossmember - 1B CROSSMEMBER - 1B Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 4 crossmember bolts. 3. Remove the 4 crossmember nuts. - To install, tighten to 103 Nm (76 lb-ft). 4. Remove the 1B crossmember. 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Crossmember - 1B > Page 8598 Rear Cross-Member: Service and Repair Transmission Support Crossmember TRANSMISSION SUPPORT CROSSMEMBER Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 4 transfer case skid plate bolts and remove the transfer case skid plate. - To install, tighten to 15 Nm (11 lb-ft). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Service and Repair > Crossmember - 1B > Page 8599 3. NOTE: Explorer/Mountaineer shown, Explorer Sport Trac similar. Remove the heat shield bolt from the RH heat shield. To install, tighten to 18 Nm (13 lb-ft). 4. Remove the heat shield bolt from the LH heat shield. - To install, tighten to 18 Nm (13 lb-ft). 5. Support the transmission with a suitable jack. 6. Remove the 2 transmission mount nuts. - To install, tighten to 90 Nm (66 lb-ft). 7. Remove the 6 transmission crossmember lower bolts. - To install, tighten to 80 Nm (59 lb-ft). 8. NOTE: Tighten the nut side of the joint. Remove the 2 upper nuts and 2 bolts from the transmission crossmember. To install, tighten to 143 Nm (105 lb-ft). 9. Remove the transmission crossmember. 10. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair Trailer Hitch: Service and Repair Trailer Hitch Material Removal and Installation NOTE: The factory rear trailer hitch crossmember is welded to the frame. The service replacement trailer hitch crossmember will be bolted to the frame. All vehicles 1. Remove the spare tire. 2. Remove the rear bumper cover. 3. Disconnect the trailer wiring harness. Explorer/Mountaineer 4. Cut the rear rails vertically at least 10-18 mm (0.39-0.70 in) behind the rear body/box mount leg. - Use Explorer/Mountaineer template No. 1. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 8603 EXPLORER/MOUNTAINEER TEMPLATE # 1, LEFT HAND INNER SIDE VIEW, RIGHT HAND SYMMETRICALLY OPPOSITE 5. Drill 18 mm (0.688 in) diameter holes for the inboard and outboard attachments to each frame rail. - For the inboard side use Explorer/Mountaineer template No. 2. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 8604 EXPLORER/MOUNTAINEER TEMPLATE # 2, LEFT HAND INNER SIDE VIEW, RIGHT HAND INNER SYMMETRICALLY OPPOSITE TO LEFT HAND INNER - For the outboard side use Explorer/Mountaineer template No. 3. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 8605 EXPLORER/MOUNTAINEER TEMPLATE # 3, LEFT HAND OUTER SIDE VIEW, RIGHT HAND INNER SYMMETRICALLY OPPOSITE TO LEFT HAND INNER Explorer Sport Trac 6. Cut the rear rails vertically at least 10-18 mm (0.39-0.70 in) behind the rear body/box mount leg. - Use Sport Trac template No. 1. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 8606 SPORT TRAC TEMPLATE # 1, LEFT HAND INNER SIDE VIEW, RIGHT HAND SYMMETRICALLY OPPOSITE 7. Drill 18 mm (0.688 in) diameter holes for the inboard and outboard attachments to each frame rail. - Use Sport Trac Template No. 2. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 8607 SPORT TRAC TEMPLATE # 2, LEFT HAND INNER SIDE VIEW, RIGHT HAND INNER SYMMETRICALLY OPPOSITE TO LEFT HAND INNER - Use Sport Trac template No. 3. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 8608 SPORT TRAC TEMPLATE # 3, LEFT HAND OUTER SIDE VIEW, RIGHT HAND INNER SYMMETRICALLY OPPOSITE TO LEFT HAND INNER All vehicles 8. De-burr the cut edges of the frame rail and the drilled holes. 9. Clean the inner and outer surfaces of the frame rails, making sure all mating surfaces are free of foreign material. 10. Apply 3 even coats of the specified anti-corrosion coating onto the inner and outer surfaces of the frame rails where bare metal is present. 11. NOTE: It may be necessary to spread apart pull together the frame rails slightly to get brackets to fit. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 8609 Insert the new trailer hitch cross member assembly into the frame. 12. Hand start all 8 bolts into the weld nuts in the hitch brackets. 13. Tighten the inboard bolts. - Tighten to 235 Nm (174 lb-ft). 14. Tighten the outboard bolts. - Tighten to 235 Nm (174 lb-ft). 15. Install the trailer wiring harness. 16. Install the rear bumper cover. 17. Install the spare tire. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations > Page 8613 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Technical Service Bulletins > Customer Interest for Grille: > 08-10-4 > May > 08 > Body - Chrome Grille Peeling/Blistering/Wrinkling Grille: Customer Interest Body - Chrome Grille Peeling/Blistering/Wrinkling TSB 08-10-4 05/26/08 CHROME GRILLE - PEELING, BLISTERING OR WRINKLING FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac ISSUE Some 2006-2008 Explorer 4dr and 2007-2008 Explorer Sport Trac vehicles may exhibit a peeling, blistering or wrinkling chrome grille. ACTION Follow the Service Procedure steps to correct the condition. NOTE BEFORE ORDERING A CHROME GRILLE VERIFY THE CONCERN IS COVERED UNDER SERVICE WARRANTY BY REVIEWING THE PARTS AND SERVICE-WARRANTY GUIDELINE-JOB AIDS-GRILLE PICTURE DICTIONARY: REFER TO THE BUMPER PICTURE DICTIONARY ON THE WEBSITE FOR EXAMPLES OF WARRANTABLE AND NON-WARRANTABLE CONDITIONS. SERVICE PROCEDURE Replace the grille using Work Shop Manual (WSM), Section 501-08. Parts Block 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 081004A 2006-2008 Explorer, 1.2 Hrs. 2007-2008 Explorer Sport Trac: Replace Grille, Includes Time To Remove And Install Bumper Cover (Do Not Use With 8200A, 17957A, 13007C) DEALER CODING CONDITION BASIC PART NO. CODE 8200 34 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Grille: > 08-10-4 > May > 08 > Body - Chrome Grille Peeling/Blistering/Wrinkling Grille: All Technical Service Bulletins Body - Chrome Grille Peeling/Blistering/Wrinkling TSB 08-10-4 05/26/08 CHROME GRILLE - PEELING, BLISTERING OR WRINKLING FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac ISSUE Some 2006-2008 Explorer 4dr and 2007-2008 Explorer Sport Trac vehicles may exhibit a peeling, blistering or wrinkling chrome grille. ACTION Follow the Service Procedure steps to correct the condition. NOTE BEFORE ORDERING A CHROME GRILLE VERIFY THE CONCERN IS COVERED UNDER SERVICE WARRANTY BY REVIEWING THE PARTS AND SERVICE-WARRANTY GUIDELINE-JOB AIDS-GRILLE PICTURE DICTIONARY: REFER TO THE BUMPER PICTURE DICTIONARY ON THE WEBSITE FOR EXAMPLES OF WARRANTABLE AND NON-WARRANTABLE CONDITIONS. SERVICE PROCEDURE Replace the grille using Work Shop Manual (WSM), Section 501-08. Parts Block 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 081004A 2006-2008 Explorer, 1.2 Hrs. 2007-2008 Explorer Sport Trac: Replace Grille, Includes Time To Remove And Install Bumper Cover (Do Not Use With 8200A, 17957A, 13007C) DEALER CODING CONDITION BASIC PART NO. CODE 8200 34 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Technical Service Bulletins > Page 8627 Grille: Service and Repair RADIATOR GRILLE - EXPLORER, EXPLORER SPORT TRAC Removal and Installation 1. Remove the front bumper cover. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Technical Service Bulletins > Page 8628 2. Remove the 2 grille-to-bumper cover screws. 3. Remove the front bumper isolator and absorber. 1. Remove the 2 pushpins. 2. Remove the 2 nuts. 4. Remove the 4 scrivets. 5. Carefully release the 14 clips and remove the grille assembly from the bumper cover. 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door Console Lamp Switch: Service and Repair Door Ajar Switch - Front Door DOOR AJAR SWITCH - FRONT DOOR Removal and Installation 1. Remove the front door latch. 2. Disconnect the front door ajar switch electrical connector. 3. Release the locking tab and rotate the front door ajar switch counterclockwise and remove the switch from the front door latch. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 8635 Console Lamp Switch: Service and Repair Door Ajar Switch - Rear Door DOOR AJAR SWITCH - REAR DOOR Removal and Installation 1. Remove the rear door latch. 2. Release the locking tab, rotate the rear door ajar switch counterclockwise and remove the switch from the rear door latch. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 8636 Console Lamp Switch: Service and Repair Door Ajar Switch - Liftgate DOOR AJAR SWITCH - LIFTGATE Removal and Installation 1. Remove the liftgate latch. 2. Release the locking tab, rotate the liftgate ajar switch counterclockwise and remove the ajar switch form the liftgate latch. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 8637 Console Lamp Switch: Service and Repair Door Ajar Switch - Liftgate Glass DOOR AJAR SWITCH - LIFTGATE GLASS Removal and Installation 1. Remove the liftgate window latch. 2. Rotate the liftgate window ajar switch counterclockwise and remove the ajar switch from the liftgate window latch. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Depowering and Repowering SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING Special Tool(s) Special Tool(s) Depowering 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. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the electrical connector on a safety canopy module. Doing so can result in safety canopy deployment. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a SRS component is being serviced, the SRS must be depowered. - 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. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box (SJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse 17 (10A) from the SJB. 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 switch to OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or installing any front or side air bag supplemental restraint system (SRS) components and before servicing, installing, 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 front impact severity sensors are located on the radiator support bracket above the lower front splash shield. The front door side impact sensors are located in the first row doors, behind the door trim panel. The C-pillar side impact sensors (if equipped) are located on the C-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). Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8643 remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install RCM fuse 17 (10A) to the SJB and close the cover. 4. 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. 5. Prove out the SRS as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch 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 6 seconds and then turn off. If an air bag SRS fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag indicator might not light 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 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 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous diagnostic trouble codes (DTCs) from the RCM and occupant classification sensor (OCS) module using a scan tool. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8644 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Deactivation and Reactivation SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION Special Tool(s) Special Tool(s) Deactivation 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. - Never probe the connectors on the safety canopy module. Doing so can result in safety canopy deployment, which can result in personal injury. - The safety belt pretensioner and adaptive load limiting retractor are pyrotechnic devices. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner/adaptive load limiting retractor. Never probe a pretensioner or adaptive load limiting retractor electrical connector. Doing so could result in pretensioner, adaptive load limiting retractor or air bag deployment and could result in personal injury. - 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a SRS component is being serviced, the SRS must be depowered. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8645 - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a SRS fault. - 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 smart junction box (SJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse 17 (10A) from the SJB. 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 front impact severity sensors are located on the radiator support bracket above the lower front splash shield. The front door side impact sensors are located in the first row doors, behind the door trim panel. The C-pillar side impact sensors (if equipped) are located on the C-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). Disconnect the battery ground cable and wait at least one minute. 7. Remove the 2 driver air bag module bolts (1 shown). 8. NOTE: Note the position of the 3 driver air bag module wiring connectors for installation. Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag module. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8646 9. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of the steering column. 10. Open and lower the glove compartment door. 11. Detach the wiring retainer, remove the 4 bolts and the passenger air bag module heat shield. 12. NOTE: Deactivate the passenger air bag module as shown, the canister vent and adaptive tether squibs do not require deactivation. Through the glove compartment opening, disconnect the LH side passenger air bag module electrical connector. 13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector on the LH side. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8647 14. From under the rear of the passenger seat, detach the passenger seat side air bag module electrical connector from the seat track bracket. Then slide and disengage the passenger seat side air bag module electrical connector locking clip, and then release the tab and disconnect the passenger seat side air bag module electrical connector. 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat side air bag module electrical connector. Vehicles without safety canopy modules 16. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy bridge resistor from the safety canopy electrical connector. If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the RCM. If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low resistance fault will be generated by the RCM. Explorer and Mountaineer vehicles with safety canopy modules 17. Release and position aside the passenger side C-pillar trim panel. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8648 18. Disconnect the passenger side safety canopy module electrical connector. 19. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. 20. Release and position aside the driver side C-pillar trim panel. 21. Disconnect the driver side safety canopy module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8649 22. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. Explorer Sport Trac vehicles with safety canopy modules 23. Remove the driver and passenger side upper C-pillar trim panels. 24. Disconnect the passenger side safety canopy module electrical connector. 25. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. 26. Disconnect the driver side safety canopy module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8650 27. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. All vehicles 28. From under the rear of the driver seat, slide and disengage the driver seat side air bag module electrical connector locking clip, and then release the tab and disconnect the driver seat side air bag module electrical connector. 29. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air bag module electrical connector. 30. Install the RCM fuse 17 (10A) to the SJB. 31. Connect the battery ground cable. Reactivation All vehicles 1. Remove the RCM fuse 17 (10A) from the SJB. 2. Disconnect the battery ground cable and wait at least one minute. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8651 3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat side air bag module electrical connector. 4. Connect the driver seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Explorer Sport Trac vehicles with safety canopy modules 5. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 6. Connect the driver side safety canopy module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8652 7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 8. Connect the passenger side safety canopy module electrical connector. 9. Install the driver and passenger upper C-pillar trim panels. Explorer and Mountaineer vehicles with safety canopy modules 10. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 11. Connect the driver side safety canopy module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8653 12. Install the driver side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. 13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 14. Connect the passenger side safety canopy module electrical connector. 15. Install the passenger side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. All vehicles Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8654 16. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat side air bag module electrical connector. 17. Connect the passenger seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Then attach the passenger seat side air bag module electrical connector to the seat track bracket. 18. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector on the LH side. 19. Connect the LH side passenger air bag module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8655 20. Install the passenger air bag module heat shield and the 4 bolts. Attach the wiring retainer. 21. Close glove compartment door. 22. Remove the restraint system diagnostic tools from the clockspring electrical connectors at the top of the steering column. 23. CAUTION: The clockspring electrical connectors are unique and cannot be connected to the driver air bag module in the wrong position. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Connect the driver air bag module electrical connectors as noted in removal. 24. Install the 2 driver air bag module bolts (1 shown). - Tighten to 7 Nm (62 lb-in). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 8656 25. 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. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 26. Turn the ignition switch from OFF to ON. 27. Install the RCM fuse 17 (10A) to the SJB and install the cover. 28. 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. 29. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the switch 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 6 seconds and then turn off. If an air bag SRS fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag indicator might not light 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 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 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and occupant classification sensor (OCS) module using a scan tool. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair Headliner: Service and Repair HEADLINER Explorer/Mountaineer (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 8660 Explorer/Mountaineer (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 8661 Explorer Sport Trac Removal and Installation Explorer and Mountaineer only 1. If equipped, remove the rear entertainment system. Explorer Sport Trac only 2. NOTE: The headliner is removed through the rear passenger door. To facilitate removal, the front passenger seat must be removed. Remove the front passenger seat. All vehicles 3. Remove the overhead console. 4. Remove the A-pillar trim panel. 5. Position the B-pillar upper trim panel aside. Explorer and Mountaineer only 6. Remove the C-pillar trim panel. 7. Remove the D-pillar trim panel. Explorer Sport Trac 8. Position the C-pillar upper trim panel aside. All vehicles 9. Remove the gimp around the roof opening panel, if equipped. 10. Remove the 4 sun visor retainer screws. 11. Remove the sun visors. 12. Carefully lower the headliner at the corner of the sun visor location to access the electrical connector and disconnect the electrical connector. 13. Disconnect the roof opening panel, if equipped. 14. Disconnect the interior mirror electrical connector and electronic compass sensor connector, if equipped. 15. Use a thin-blade tool and carefully remove the dome lamp cover. 16. Disconnect the dome lamp electrical connectors. Explorer and Mountaineer only 17. Remove the upper air duct. - Remove the pin-type retainers. - Push down on the duct, tilt the top outward and pull upward to remove. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 8662 18. Remove the lower air duct. 19. Disconnect the electrical connector located at the C-pillar. - Release the wiring harness pin-type retainers. 20. Disconnect all the electrical connectors. All vehicles 21. Disconnect the electrical connector and the wiring pin-type retainers on the A-pillar. 22. CAUTION: To prevent bending or damaging the headliner, an assistant is required to support the headliner while carrying out the remaining steps. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 8663 Open the sun visor center retainer cover and remove the screw. 23. Remove the sun visor center retainer. 24. Remove the rear pin-type retainer. 25. CAUTION: To prevent damaging the garment hanger retainer, use a 3/16-inch flat-blade screwdriver to carry out this step. NOTE: The garment hanger is shown without the roof sheet metal screw to show the metal retainer clip. The metal retainer clip will remain engaged in the sheet metal after the garment hanger is removed. Remove the garment hangers. 1. Open the access door. 2. Insert the flat-blade screwdriver fully into the garment hanger slot. 3. Rotate the screwdriver 90 degrees so that the screwdriver spreads the metal retainer clip. Remove the plastic garment hanger. 26. NOTE: The headliner is removed through the passenger rear door for Explorer Sport Trac. Remove the headliner. 27. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > Customer Interest for Sun Visor: > 09-2-9 > Feb > 09 > Interior - Sun Visor Mirror Cover Cracked Sun Visor: Customer Interest Interior - Sun Visor Mirror Cover Cracked TSB 09-2-9 02/09/09 SUN VISOR MIRROR COVER CRACKING - BUILT BETWEEN 1/212007 AND 11/3/2008 FORD: 2007-2009 Explorer Sport Trac, Explorer MERCURY: 2007-2009 Mountaineer ISSUE Some 2007-2009 Explorer, Mountaineer and Sport Trac vehicles equipped with camel color sun visors built between 1/2/2007 and 11/3/2008 may exhibit a crack in the plastic at the sun visor mirror cover hinge. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Replace all affected sun visors with new updated parts. 2. Remove the two (2) sun visor screws on the affected side and disconnect the electrical connector. 3. To install, reverse the removal procedure. Parts Block 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 090209A 2007-2009 Explorer, 0.3 Hr. Mountaineer, Sport Trac: Replace ONE Sun Visor (Do Not Use With 04104A) 090209B 2007-2009 Explorer, 0.4 Hr. Mountaineer, Sport Trac: Replace BOTH Sun Visors (Do Not Use With 04104A) DEALER CODING Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > Customer Interest for Sun Visor: > 09-2-9 > Feb > 09 > Interior - Sun Visor Mirror Cover Cracked > Page 8672 CONDITION BASIC PART NO. CODE 7804104 D4 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Visor: > 09-2-9 > Feb > 09 > Interior - Sun Visor Mirror Cover Cracked Sun Visor: All Technical Service Bulletins Interior - Sun Visor Mirror Cover Cracked TSB 09-2-9 02/09/09 SUN VISOR MIRROR COVER CRACKING - BUILT BETWEEN 1/212007 AND 11/3/2008 FORD: 2007-2009 Explorer Sport Trac, Explorer MERCURY: 2007-2009 Mountaineer ISSUE Some 2007-2009 Explorer, Mountaineer and Sport Trac vehicles equipped with camel color sun visors built between 1/2/2007 and 11/3/2008 may exhibit a crack in the plastic at the sun visor mirror cover hinge. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Replace all affected sun visors with new updated parts. 2. Remove the two (2) sun visor screws on the affected side and disconnect the electrical connector. 3. To install, reverse the removal procedure. Parts Block 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 090209A 2007-2009 Explorer, 0.3 Hr. Mountaineer, Sport Trac: Replace ONE Sun Visor (Do Not Use With 04104A) 090209B 2007-2009 Explorer, 0.4 Hr. Mountaineer, Sport Trac: Replace BOTH Sun Visors (Do Not Use With 04104A) DEALER CODING Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Visor: > 09-2-9 > Feb > 09 > Interior - Sun Visor Mirror Cover Cracked > Page 8678 CONDITION BASIC PART NO. CODE 7804104 D4 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 A-PILLAR TRIM PANEL Explorer And Mountaineer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A - Pillar Trim Panel > Page 8683 Explorer Sport Trac Exploded Views Removal and Installation 1. Remove the 2 assist handle bolt covers. 2. Remove the 2 assist handle bolts. - To install, tighten to 10 Nm (89 lb-in). 3. Remove the assist handle. 4. Position the door opening weatherstrip aside. 5. NOTE: The clip on the LH A-pillar trim panel must remain in the sheet metal. The clip comes off the A-pillar trim panel when the panel is removed. Remove the A-pillar trim panel. 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A - Pillar Trim Panel > Page 8684 Trim Panel: Service and Repair B-Pillar Lower Trim Panel B-PILLAR LOWER TRIM PANEL Explorer And Mountaineer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A - Pillar Trim Panel > Page 8685 Explorer Sport Trac Exploded Views Removal and Installation 1. Remove the front and rear door scuff plates. 2. Position the door opening weatherstrip aside. 3. Remove the B-pillar lower trim panel. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A - Pillar Trim Panel > Page 8686 Trim Panel: Service and Repair B-Pillar Upper Trim Panel B-PILLAR UPPER TRIM PANEL Explorer And Mountaineer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A - Pillar Trim Panel > Page 8687 Explorer Sport Trac Exploded Views Removal and Installation 1. Remove the B-pillar lower trim panel. 2. Remove the D-ring safety belt anchor bolt. - To install, tighten to 40 Nm (30 lb-ft). 3. Position the door opening weatherstrip aside. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A - Pillar Trim Panel > Page 8688 4. Remove the B-pillar upper trim panel retaining clip from the lower right corner of the panel. 5. Remove the B-pillar upper trim panel retaining clip from the upper left of the panel. 6. To install, reverse the removal procedure. - Be sure the hole on the back of the B-pillar upper trim panel is seated over the safety belt D-ring bolt. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A - Pillar Trim Panel > Page 8689 Trim Panel: Service and Repair C-Pillar Trim Panel C-PILLAR TRIM PANEL - EXPLORER, MOUNTAINEER Explorer And Mountaineer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A - Pillar Trim Panel > Page 8690 Explorer Sport Trac Exploded Views Removal and Installation Second row bucket 1. Position the second row seat to the forward position. Second row bench 2. Remove the second row seat. All vehicles 3. Remove the C-pillar lower safety belt anchor bolt. - To install, tighten to 40 Nm (30 lb-ft). 4. Position the door opening weatherstrip aside. 5. Remove the C-pillar trim panel. 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A - Pillar Trim Panel > Page 8691 - Be sure the hole on the back of the C-pillar upper trim panel is seated over the upper safety belt anchor bolt. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A - Pillar Trim Panel > Page 8692 Trim Panel: Service and Repair A - Pillar Trim Panel A-PILLAR TRIM PANEL Explorer And Mountaineer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A - Pillar Trim Panel > Page 8693 Explorer Sport Trac Exploded Views Removal and Installation 1. Remove the 2 assist handle bolt covers. 2. Remove the 2 assist handle bolts. - To install, tighten to 10 Nm (89 lb-in). 3. Remove the assist handle. 4. Position the door opening weatherstrip aside. 5. NOTE: The clip on the LH A-pillar trim panel must remain in the sheet metal. The clip comes off the A-pillar trim panel when the panel is removed. Remove the A-pillar trim panel. 6. To install, reverse the removal procedure. B-Pillar Lower Trim Panel Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A - Pillar Trim Panel > Page 8694 B-PILLAR LOWER TRIM PANEL Explorer And Mountaineer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A - Pillar Trim Panel > Page 8695 Explorer Sport Trac Exploded Views Removal and Installation 1. Remove the front and rear door scuff plates. 2. Position the door opening weatherstrip aside. 3. Remove the B-pillar lower trim panel. 4. To install, reverse the removal procedure. B-Pillar Upper Trim Panel B-PILLAR UPPER TRIM PANEL Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A - Pillar Trim Panel > Page 8696 Explorer And Mountaineer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A - Pillar Trim Panel > Page 8697 Explorer Sport Trac Exploded Views Removal and Installation 1. Remove the B-pillar lower trim panel. 2. Remove the D-ring safety belt anchor bolt. - To install, tighten to 40 Nm (30 lb-ft). 3. Position the door opening weatherstrip aside. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A - Pillar Trim Panel > Page 8698 4. Remove the B-pillar upper trim panel retaining clip from the lower right corner of the panel. 5. Remove the B-pillar upper trim panel retaining clip from the upper left of the panel. 6. To install, reverse the removal procedure. - Be sure the hole on the back of the B-pillar upper trim panel is seated over the safety belt D-ring bolt. C-Pillar Trim Panel C-PILLAR TRIM PANEL - EXPLORER, MOUNTAINEER Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A - Pillar Trim Panel > Page 8699 Explorer And Mountaineer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A - Pillar Trim Panel > Page 8700 Explorer Sport Trac Exploded Views Removal and Installation Second row bucket 1. Position the second row seat to the forward position. Second row bench 2. Remove the second row seat. All vehicles 3. Remove the C-pillar lower safety belt anchor bolt. - To install, tighten to 40 Nm (30 lb-ft). 4. Position the door opening weatherstrip aside. 5. Remove the C-pillar trim panel. 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A - Pillar Trim Panel > Page 8701 - Be sure the hole on the back of the C-pillar upper trim panel is seated over the upper safety belt anchor bolt. Cab Rear Trim Panel CAB REAR TRIM PANEL Explorer Sport Trac Exploded Views Removal and Installation 1. Position the second row seat back forward. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A - Pillar Trim Panel > Page 8702 2. Remove the 2 screws from the storage compartment. 3. NOTE: When removing the cab rear trim panel, start in the upper left corner, moving clockwise and remove the panel from the retaining clips. Remove the rear trim panel. 4. To install, reverse the removal procedures. Cowl Side Trim Panel COWL SIDE TRIM PANEL Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A - Pillar Trim Panel > Page 8703 Explorer And Mountaineer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A - Pillar Trim Panel > Page 8704 Explorer Sport Trac Exploded Views Removal and Installation All vehicles 1. Remove the front door scuff plate. Passenger side 2. Remove the cowl trim panel. Driver side Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A - Pillar Trim Panel > Page 8705 3. Remove the hood release lever. 1. Remove the screw. 2. Remove the hood release lever. 4. Remove the cowl trim panel. 1. Remove the pin-type retainer. 2. Remove the cowl trim panel. All vehicles 5. To install, reverse the removal procedure. D-Pillar Trim Panel D-PILLAR TRIM PANEL Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A - Pillar Trim Panel > Page 8706 Explorer And Mountaineer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A - Pillar Trim Panel > Page 8707 Explorer Sport Trac Exploded Views Removal and Installation Vehicles with third row seating Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A - Pillar Trim Panel > Page 8708 1. Remove the rear cargo management system. - Remove the screw. - Remove the pushpin. - Remove the system. 2. Remove the D-pillar lower safety belt anchor bolt. - To install, tighten to 40 Nm (30 lb-ft). All vehicles 3. Position the liftgate opening weatherstrip aside. 4. Remove the rear upper headliner trim panel. 5. Remove the D-pillar trim panel. 6. To install, reverse the removal procedure. Quarter Trim Panel QUARTER TRIM PANEL Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A - Pillar Trim Panel > Page 8709 Explorer And Mountaineer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A - Pillar Trim Panel > Page 8710 Explorer Sport Trac Exploded Views Removal and Installation 1. Remove the rear door scuff plate. 2. Remove the C-pillar trim panel. 3. Remove the D-pillar trim panel. 4. Remove the liftgate scuff plate trim panel. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A - Pillar Trim Panel > Page 8711 5. Remove the luggage compartment assembly cover, if equipped. 6. Remove the stowage compartment doors. 7. Position the carpet aside. 8. Remove the rear quarter trim panel. 9. Disconnect the electrical connectors, if necessary. 10. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair Door Lock Cylinder: Service and Repair DOOR LOCK CYLINDER Removal and Installation NOTE: - When any new lock cylinder is installed, the driver door and ignition lock cylinders should be installed as a set. This eliminates carrying an extra key which fits only 1 lock. If a new key is used, 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. Position the watershield aside. 3. Release the front door push button rod from the door frame retainer. 4. Remove the exterior front door handle nut (rear). - To install, tighten to 9 Nm (80 lb-in). 5. Remove the door lock cylinder. - Disconnect the front door lock cylinder actuating rod. 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Locations View 151-21 (Driver Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Locations > Page 8721 C500 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Locations > Page 8722 Keyless Entry Key-Pad: Testing and Inspection KEYLESS ENTRY KEYPAD CODE PROGRAMMING NOTE: A maximum of 3 personal entry codes can be programmed into the vehicle. The personal entry codes can be associated with up to two memory seat/adjustable pedal settings. 1. Enter the permanent factory keyless entry keypad code. 2. Press the 1/2 button within 5 seconds to activate the programming mode. Holding the 1/2 button for more than 2 seconds after activation erases all the stored customer codes. The existing codes do not need to be erased to program a new code. 3. Within 5 seconds, enter the new 5-digit keyless entry keypad code. 4. Press the 1/2, 3/4, or 5/6 to indicate which of the three personal entry code positions is to be programmed. 5. The door locks lock and unlock to confirm the new code is programmed. 6. To program an additional personal entry code, REPEAT steps 2 through 4. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Locations > Page 8723 Keyless Entry Key-Pad: Service and Repair KEYLESS ENTRY KEYPAD Removal and Installation 1. Position the front window glass to the full down position. 2. Position the door glass top run aside to access the door pillar trim panel screws. 3. Remove the 3 door pillar trim panel screws and the door pillar trim panel. 4. Disconnect the electrical connector and remove the keyless entry keypad from the door pillar trim panel. 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry Transmitter Programming Keyless Entry Transmitter: Testing and Inspection Remote Keyless Entry Transmitter Programming REMOTE KEYLESS ENTRY TRANSMITTER PROGRAMMING NOTE: - All remote keyless entry (RKE) transmitters must be programmed at the same time. - Programming of the RKE transmitters can be accomplished using a scan tool or by carrying out the following steps: 1. The vehicle must be electronically unlocked before entering program mode using the RKE transmitter, keyless entry keypad (if equipped) or door lock control switch while the driver door is open. 2. Turn the key from OFF to RUN 8 times within 10 seconds, with the eighth turn ending in RUN. If the module successfully enters the program mode, it locks and then unlocks all doors. 3. Within 20 seconds, press any button on an RKE transmitter, and the doors lock and then unlock to confirm that each RKE transmitter is programmed. Repeat this step for each RKE transmitter. 4. If the door locks do not respond for any RKE transmitter, wait several seconds and press the button again. If the door locks still fail to respond, refer to Inspection and Verification. Make sure that no more than the maximum number of 6 RKE transmitters are attempted to be programmed. See: Power Locks/Testing and Inspection/Initial Inspection and Diagnostic Overview/Inspection and Verification 5. Exiting the programming mode is accomplished if one of the following occurs: - The key transitions to the OFF position. Twenty seconds have passed since entering programming mode or since the last RKE transmitter was programmed. - The maximum number of 6 RKE transmitters have been programmed. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry Transmitter Programming > Page 8728 Keyless Entry Transmitter: Testing and Inspection Autolock and Horn Chirp Programming AUTOLOCK AND HORN CHIRP PROGRAMMING Autolock Programming Using the Keyless Entry Keypad 1. Close all doors and windows. 2. Confirm that the ignition key is OFF. 3. Enter the 5-digit permanent entry code into the keyless entry keypad. 4. Within 5 seconds of entering the code, press and hold the 3/4 button on the keyless entry keypad. 5. Within 5 seconds of Step 3, and while holding the 3/4 button, press the 7/8 button on the keyless entry keypad and release it. 6. NOTE: If the autolock is disabled, the horn chirps once. If the autolock feature is enabled, the horn chirps once shortly and then sounds a second time with a longer sound of the horn once the above sequence is completed. Within 5 seconds of Step 3, release the 3/4 button on the keyless entry keypad. Autolock Programming Using the Ignition Lock Cylinder 1. Close all doors and windows. 2. Confirm that the ignition key is OFF. 3. NOTE: Steps 5 through 9 must be carried out within 30 seconds. Turn the ignition key from OFF to RUN. 4. Press the door lock control switch UNLOCK button 3 times. 5. Turn the ignition key from RUN to OFF. 6. Press the door lock control switch UNLOCK button 3 times. 7. Turn the ignition key from OFF to RUN. 8. Verify the horn chirps. This indicates the enable/disable mode and now is ready to accept program changes. 9. Press the door lock control switch UNLOCK button then the LOCK button 1 time to command the module to toggle the autolock/relock feature. 10. Verify that the horn chirps. There should be 1 chirp indicating that autolock/relock feature has been disabled. If 1 chirp is heard, followed by a longer sound of the horn, the autolock/relock feature has just been enabled. 11. Turn the key to the OFF position or wait 2 minutes to exit the enable/disable mode. 12. Verify that the horn chirps once to indicate that a feature has been changed and that autolock/relock has been toggled. Auto-Unlock Programming Using the Keyless Entry Keypad 1. Close all doors and windows. 2. Confirm that the ignition key is OFF. 3. Enter the 5-digit permanent entry code into the keyless entry keypad. 4. Within 5 seconds of entering the code, press and hold the 3/4 button on the keyless entry keypad. 5. Within 5 seconds of Step 3, and while holding the 3/4 button, press the 7/8 button twice on the keyless entry keypad and release it. 6. NOTE: If the auto-unlock is disabled, the horn chirps once. If the auto-unlock feature is enabled, the horn chirps twice. Within 5 seconds of Step 3, release the 3/4 button on the keyless entry keypad. Auto-Unlock Programming Using the Ignition Lock Cylinder 1. Close all doors and windows. 2. Confirm that the ignition key is OFF. 3. NOTE: Steps 5 through 9 must be carried out within 30 seconds. Turn the ignition key from OFF to RUN. 4. Press the door lock control switch UNLOCK button 3 times. 5. Turn the ignition key from RUN to OFF. 6. Press the door lock control switch UNLOCK button 3 times. 7. Turn the ignition key from OFF to RUN. 8. Verify the horn chirps. This indicates the enable/disable mode and now is ready to accept program changes. 9. Press the door lock control switch LOCK button then the UNLOCK button 1 time to command the module to toggle the auto-unlock feature. 10. Verify that the horn chirps. There should be 1 chirp indicating that auto-unlock feature has been disabled. If 1 chirp is heard, followed by a longer sound of the horn, the auto-unlock feature has just been enabled. 11. Turn the key to the OFF position or wait 2 minutes to exit the enable/disable mode. 12. Verify that the horn chirps once to indicate that a feature has been changed and that auto-unlock has been toggled. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > Procedures Keyless Entry Transmitter: Procedures Remote Memory Activation REMOTE MEMORY ACTIVATION 1. Position the driver seat and adjustable pedals to the desired position. 2. Press the set button on the lower center of the instrument panel. 3. Within 5 seconds press one control on the remote keyless entry (RKE) transmitter and then the 1 or 2 button on the lower center of the instrument panel to associate the RKE transmitter to the driver 1 or the driver 2 position. This stores the configuration for driver 1 or driver 2. 4. If a second memory setting is desired, repeat the procedure with the second RKE transmitter. Remote Memory Deactivation REMOTE MEMORY DEACTIVATION 1. Press the set button on the lower center of the instrument panel. 2. Within 5 seconds press one control on the remote keyless entry (RKE) transmitter and then the set button on the lower center of the instrument panel to associate the RKE transmitter to the driver 1 or the driver 2 position. 3. If a second memory setting is desired to be deactivated, repeat the procedure with the second RKE transmitter. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair > Procedures > Page 8731 Keyless Entry Transmitter: Removal and Replacement TAILGATE LATCH REMOTE CONTROL Removal and Installation 1. Open and support the tailgate. 2. Remove the 7 bolts, the 4 pin-type retainers and the tailgate access panel. - To install, tighten to 5 Nm (44 lb-in). 3. Open the 2 clips and release the 2 tailgate latch actuating rods from the tailgate remote control. 4. Release the 2 tailgate latch actuating rod locators from the tailgate. 5. Remove the 2 nuts and the tailgate remote control. - To install, tighten to 9 Nm (80 lb-in). 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Lock Actuator, Driver Side View 151-21 (Driver Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Lock Actuator, Driver Side > Page 8737 View 151-22 (Passenger Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Lock Actuator, Driver Side > Page 8738 View 151-24 (Left Rear Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Lock Actuator, Driver Side > Page 8739 View 151-23 (Right Rear Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Actuator, Driver Side C525 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Actuator, Driver Side > Page 8742 C603 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Actuator, Driver Side > Page 8743 C704 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Actuator, Driver Side > Page 8744 C804 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Front Door Lock Actuator Power Door Lock Actuator: Service and Repair Front Door Lock Actuator FRONT DOOR LOCK ACTUATOR Removal and Installation 1. Remove the front door latch. 2. Disconnect the front door ajar switch and the front door lock actuator electrical connectors. 3. Release the locking tab and remove the front door lock actuator. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Front Door Lock Actuator > Page 8747 Power Door Lock Actuator: Service and Repair Rear Door Lock Actuator REAR DOOR LOCK ACTUATOR Removal and Installation 1. Remove the rear door latch. 2. Release the locking tab and remove the rear door lock actuator. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side View 151-22 (Passenger Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side > Page 8752 View 151-21 (Driver Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side C505 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side > Page 8755 C605 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 8756 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 8757 Power Door Lock Switch: Service and Repair DOOR LOCK CONTROL SWITCH Removal and Installation NOTE: The LH side is shown, the RH side is similar. 1. Remove the interior door handle cover. 2. Remove the front door switch bezel. - Release the 4 retaining tabs. 3. Disconnect the door lock control switch and window control switch electrical connectors. 4. Remove the door lock control switch. - Release the 4 retaining tabs. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 8758 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair TAILGATE LOCK CYLINDER Removal and Installation NOTE: - When a new lock cylinder is installed, the tailgate lock cylinder, door lock cylinders and the ignition lock cylinder should be installed as a set. This eliminates carrying an extra key which fits only 1 lock. If a new key is to be used, the new key code is attached to a tag. - The individual door lock cylinders are repaired by discarding the inoperative lock cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build a new lock cylinder to the current key code of the vehicle. 1. Remove the tailgate release handle. 2. Remove retaining clip and the tailgate lock cylinder. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations View 151-19 (Driver Seat) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 8767 Memory Positioning Module: Diagrams C341A C341B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 8768 C341C Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 8769 Memory Positioning Module: Description and Operation Memory Adjustable Pedal Operation The adjustable pedals with memory feature is controlled by using the memory switches or the remote keyless entry (RKE) transmitter. The exterior mirror and power driver seat positions are also stored and recalled with the power adjustable pedal positions. The system can store 3 memory settings. Driver Seat Module (DSM) The DSM controls the memory adjustable pedals. The DSM constantly monitors the systems under its control and records concerns in the form of diagnostic trouble codes (DTCs). A DTC can be retrieved with the scan tool through the data link connector (DLC). Memory Adjustable Pedal Operation The adjustable pedals with memory feature is controlled by using the memory switches or the remote keyless entry (RKE) transmitter. The exterior mirror and power driver seat positions are also stored and recalled with the power adjustable pedal positions. The system can store 3 memory settings. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Belt Tower Position Sensor > Component Information > Description and Operation Seat Belt Tower Position Sensor: Description and Operation SEAT TRACK POSITION SENSOR The seat track position sensor is a Hall-effect sensor located on the driver seat track. The seat track position sensor informs the RCM of the driver seat position. Based on programmed limits, the seat track position sensor will inform the RCM of the driver seat position. The RCM uses this information in determining the deployment rate of the dual-stage driver air bag module. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 8776 C2094 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Service and Repair Power Mirror Motor: Service and Repair EXTERIOR MIRROR MOTOR Exploded View Removal and Installation NOTE: RH shown, LH similar. 1. Remove the exterior mirror glass. 2. Remove the exterior mirror motor screws. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Service and Repair > Page 8780 3. Disconnect the exterior mirror motor electrical connectors. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations View 151-21 (Driver Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 8784 C527 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 8785 Power Mirror Switch: Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 8786 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 8787 Power Mirror Switch: Service and Repair EXTERIOR MIRROR CONTROL SWITCH Removal and Installation 1. Remove the front door trim panel. 2. Remove the exterior mirror control switch from the front door trim panel. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes Paint: Application and ID Paint Codes PAINT CODES Vehicle Certification Label Exterior Paint Code Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 8793 Exterior Paint Exterior paint codes may be listed as a 2-part code. The first set of characters identify the primary body color. The second set of characters (if applicable) identify the vehicle accent or 2-tone body color. All colors are base coat/clear coat. Primary Exterior Color Codes DX - Dark Blue Pearl - Explorer/Explorer Sport Trac - G2 - Redfire - Explorer/Mountaineer/Explorer Sport Trac - G3 - Pueblo Gold - Explorer/Mountaineer/Explorer Sport Trac - G5 - Alloy Gray - Explorer/Mountaineer/Explorer Sport Trac - HH - Dark Cherry - Explorer/Mountaineer/Explorer Sport Trac - JP - Silver Birch Metallic - Explorer/Mountaineer/Explorer Sport Trac - NL - Orange Frost - Explorer/Explorer Sport Trac - PV - White Chocolate (tri-coat) - Explorer/Mountaineer - T7 - Dark Stone - Explorer/Mountaineer/Explorer Sport Trac - TK - Mineral Gray Metallic - Explorer Sport Trac - UA - Ebony - Explorer/Mountaineer/Explorer Sport Trac - YZ - Oxford White - Explorer/Mountaineer/Explorer Sport Trac Exterior Accent Color Codes G3 - Pueblo Gold - Explorer Interior Trim Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 8794 Interior Trim Interior trim codes are Listed as a 2-part code. The first character identifies the interior trim type. The second character identifies the interior trim color. Interior Trim Type 3 - Imola perforated leather seats - Mountaineer - 4 - Imola perforated Leather with heated driver seat - Mountaineer - 8 - Embossed Leather with preferred suede insert seats - Mountaineer - I - Imola/Milled Pebble Leather with power, heated driver and passenger seats - Explorer - R - Treads cloth seats - Explorer/Explorer Sport Trac - S - Treads cloth with power driver seat - Explorer/Mountaineer/Explorer Sport Trac - T - Imola/Milled Pebble Leather with power, heated driver seat and memory - Explorer/Explorer Sport Trac - V - Imola/Milled Pebble Leather with power driver seat - Explorer - W - Leather trim with Preferred smooth suede inserts and power driver seat - Explorer - X - Leather trim with Preferred smooth suede inserts and power/heated/memory driver seat Explorer - Z - Imola/Milled Pebble Leather with power/heated/memory driver seat - Explorer Interior Trim Color C - Camel - Explorer/Mountaineer/Explorer Sport Trac - L - Medium Light Stone - Explorer/Mountaineer/Explorer Sport Trac - W - Charcoal Black - Explorer/Mountaineer/Explorer Sport Tape/Paint Stripe Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 8795 Tape/Paint Stripe Tape and paint stripe codes do not apply. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 8796 Paint: Application and ID Paint Code Sticker Location PAINT CODE STICKER LOCATION Vehicle Certification (VC) Label Locator Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations View 151-19 (Driver Seat) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 8801 Memory Positioning Module: Diagrams C341A C341B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 8802 C341C Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 8803 Memory Positioning Module: Description and Operation Memory Adjustable Pedal Operation The adjustable pedals with memory feature is controlled by using the memory switches or the remote keyless entry (RKE) transmitter. The exterior mirror and power driver seat positions are also stored and recalled with the power adjustable pedal positions. The system can store 3 memory settings. Driver Seat Module (DSM) The DSM controls the memory adjustable pedals. The DSM constantly monitors the systems under its control and records concerns in the form of diagnostic trouble codes (DTCs). A DTC can be retrieved with the scan tool through the data link connector (DLC). Memory Adjustable Pedal Operation The adjustable pedals with memory feature is controlled by using the memory switches or the remote keyless entry (RKE) transmitter. The exterior mirror and power driver seat positions are also stored and recalled with the power adjustable pedal positions. The system can store 3 memory settings. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Pedal Positioning Module > Component Information > Description and Operation Pedal Positioning Module: Description and Operation Adjustable Pedals Using the adjustable pedal switch located on the instrument panel, the driver can adjust the brake and accelerator pedals for a more comfortable driving position. For removal and installation of the adjustable pedals, refer to Brake Pedal and Bracket. Adjustable Pedal Operation The adjustable pedals with or without memory feature are operational with the ignition switch in the ON or OFF position. The pedals are adjusted forward or rearward using the adjustable pedal switch. Memory Adjustable Pedal Operation The adjustable pedals with memory feature is controlled by using the memory switches or the remote keyless entry (RKE) transmitter. The exterior mirror and power driver seat positions are also stored and recalled with the power adjustable pedal positions. The system can store 3 memory settings. Driver Seat Module (DSM) The DSM controls the memory adjustable pedals. The DSM constantly monitors the systems under its control and records concerns in the form of diagnostic trouble codes (DTCs). A DTC can be retrieved with the scan tool through the data link connector (DLC). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Locations View 151-15 (Left Rear, (1 0f 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Diagrams > Third Row Folding Seat Relay, Left C4183 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Diagrams > Third Row Folding Seat Relay, Left > Page 8812 C4184 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 8815 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Auxiliary Step / Running Board Module > Component Information > Service and Repair Auxiliary Step / Running Board Module: Service and Repair RETRACTABLE RUNNING BOARD MODULE Removal and Installation 1. Remove the RH C-pillar trim panel. 2. Disconnect the retractable running board module electrical connectors. 3. Remove the 3 screws and the retractable running board module assembly. - To install, tighten to 7 Nm (62 lb-in). 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations View 151-26 (Roof) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 8822 C921 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations > Page 8826 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Limit Switch > Component Information > Service and Repair Sunroof / Moonroof Limit Switch: Service and Repair ROOF OPENING PANEL CONTROL SWITCH Removal and Installation 1. Remove the overhead console. 2. Disconnect the overhead console electrical connectors. 3. Disengage the clips and remove the switch from the overhead console. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair Sunroof / Moonroof Motor: Service and Repair ROOF OPENING PANEL MOTOR Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Page 8835 Part 2 Exploded Views Removal and Installation CAUTION: The roof opening panel motor contains ceramic magnets that may fail at any time if cracked. Any roof opening panel motor that has been dropped onto a hard surface during removal or installation should be replaced with a new motor. NOTE: The roof opening panel motor must be initialized when repairs are carried out on any part of the roof opening panel system, including: whenever the roof opening panel motor has been removed from the roof opening panel system, the roof opening panel glass has been removed from the roof opening panel system, the roof opening panel assembly has been removed from the vehicle, a new roof opening panel motor has been installed, a new roof opening panel glass has been installed or a new roof opening panel assembly has been installed. Refer to Roof Opening Panel Motor Initialization. See: Service and Repair/Procedures/Roof Opening Panel Motor Initialization 1. NOTE: Make sure that the roof opening panel glass is in the CLOSED position before removal. Remove the overhead console. 2. Disconnect the roof opening panel electrical connectors. 3. Remove the 3 roof opening panel motor screws. - To install, tighten to 3 Nm (27 lb-in). 4. NOTE: - When installing the roof opening panel motor, it may be necessary to turn the roof opening panel motor slightly to engage the drive splines. - Anytime a roof opening panel motor is removed, the cables/mechanisms can experience free-play movement. It is important that the cables/mechanisms do not move. They are timed to be parallel with each other. Remove the roof opening panel motor. 5. To install, reverse the removal procedure. - Initialize the roof opening panel motor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations View 151-26 (Roof) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Page 8839 Sunroof / Moonroof Switch: Diagrams C912 C9001 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair Sunroof / Moonroof Windguard: Service and Repair AIR DEFLECTOR Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Page 8843 Part 2 Exploded Views Removal and Installation 1. Move roof opening panel to full OPEN position. 2. Remove the air deflector. - Remove the 4 screws. To install, tighten to 1 Nm (9 lb-in). - Remove the air deflector from the roof opening panel frame. 3. To install, reverse the removal procedure. - Initialize the roof opening panel motor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Drain: > 07-20-6 > Oct > 07 > Body - Water Leak In The Headliner/Dome Lamp Area Sunroof / Moonroof Drain: Customer Interest Body - Water Leak In The Headliner/Dome Lamp Area TSB 07-20-6 10/15/07 WATER LEAK IN HEADLINER/DOME LAMP AREA - VEHICLES EQUIPPED WITH ROOF OPENING PANEL AND SAFETY CANOPY AIR BAG SYSTEMS - BUILT BEFORE 3/27/2007 FORD: 2006-2007 Explorer MERCURY: 2006-2007 Mountaineer This article supersedes TSB 06-21-17 to update the Part List and Service Procedure. ISSUE Some 2006-2007 Explorer and Mountaineer vehicles built prior to 3/27/2007 and equipped with factory installed roof opening panel and safety canopy air bag system may have water leaking in the headliner dome lamp area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE The procedure will reroute roof opening panel drain hoses to provide downward slope for improved drainage. 1. Remove headliner following Workshop Manual (WSM), Section 501-05. 2. Remove rear portion of drain hose from clip and remove retaining clip. NOTE IF A HOLE HAS BEEN DRILLED IN THE LOWER REAR CORNER OF THE RECTANGLE BRACKET (FIGURE 1) GO TO STEP 5. IF THE VEHICLE WAS BUILD AFTER 8/14/2006 DRILLING A 1/4" HOLE IS NOT REQUIRED. 3. Drill a 1/4" (6.7 mm) hole, 3/4" (20 mm) rearward from the lower rear corner of the rectangle. (Figure 1) CAUTION TO PREVENT DAMAGE TO OUTER SKIN SHEET METAL USE A DRILL STOP AND DO NOT ALLOW THE DRILL BIT TO STRIKE OUTER PANEL AS IT PASSES THROUGH THE INNER PANEL. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Drain: > 07-20-6 > Oct > 07 > Body - Water Leak In The Headliner/Dome Lamp Area > Page 8852 4. Remove the rear drain tube. Attach hose clip to existing hole for vehicle built after 8/14/2006. For all other vehicles attach the hose clip in the new hole. (Figure 2) 5. Install the updated drain tube. 6. Attach the hose clip to the coat hook support bracket. (Figure 3) NOTE Make sure the drain hose is placed under the coat hook bracket. (Figure 3) 7. Make sure there is no slack left in the hose as it leads up to the roof opening panel module. (Figure 3) 8. Repeat procedure on opposite side. 9. Install headliner following WSM, Section 501-05. Parts Block 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 072006A 2006-2007 Built Before 1.9 Hrs. 3/27/2007 With Roof Opening Panel And Safety Canopy: Install The Updated Drain Tubes Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Drain: > 07-20-6 > Oct > 07 > Body - Water Leak In The Headliner/Dome Lamp Area > Page 8853 Following Service Procedure, Includes Time To Remove And Install Headliner And DVD Player If Equipped (Do Not Use With 51916A, 51916B, 51916AZV, 51916BZV) DEALER CODING CONDITION BASIC PART NO. CODE 78502C53 12 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Drain: > 07-20-6 > Oct > 07 > Body - Water Leak In The Headliner/Dome Lamp Area Sunroof / Moonroof Drain: All Technical Service Bulletins Body - Water Leak In The Headliner/Dome Lamp Area TSB 07-20-6 10/15/07 WATER LEAK IN HEADLINER/DOME LAMP AREA - VEHICLES EQUIPPED WITH ROOF OPENING PANEL AND SAFETY CANOPY AIR BAG SYSTEMS - BUILT BEFORE 3/27/2007 FORD: 2006-2007 Explorer MERCURY: 2006-2007 Mountaineer This article supersedes TSB 06-21-17 to update the Part List and Service Procedure. ISSUE Some 2006-2007 Explorer and Mountaineer vehicles built prior to 3/27/2007 and equipped with factory installed roof opening panel and safety canopy air bag system may have water leaking in the headliner dome lamp area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE The procedure will reroute roof opening panel drain hoses to provide downward slope for improved drainage. 1. Remove headliner following Workshop Manual (WSM), Section 501-05. 2. Remove rear portion of drain hose from clip and remove retaining clip. NOTE IF A HOLE HAS BEEN DRILLED IN THE LOWER REAR CORNER OF THE RECTANGLE BRACKET (FIGURE 1) GO TO STEP 5. IF THE VEHICLE WAS BUILD AFTER 8/14/2006 DRILLING A 1/4" HOLE IS NOT REQUIRED. 3. Drill a 1/4" (6.7 mm) hole, 3/4" (20 mm) rearward from the lower rear corner of the rectangle. (Figure 1) CAUTION TO PREVENT DAMAGE TO OUTER SKIN SHEET METAL USE A DRILL STOP AND DO NOT ALLOW THE DRILL BIT TO STRIKE OUTER PANEL AS IT PASSES THROUGH THE INNER PANEL. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Drain: > 07-20-6 > Oct > 07 > Body - Water Leak In The Headliner/Dome Lamp Area > Page 8859 4. Remove the rear drain tube. Attach hose clip to existing hole for vehicle built after 8/14/2006. For all other vehicles attach the hose clip in the new hole. (Figure 2) 5. Install the updated drain tube. 6. Attach the hose clip to the coat hook support bracket. (Figure 3) NOTE Make sure the drain hose is placed under the coat hook bracket. (Figure 3) 7. Make sure there is no slack left in the hose as it leads up to the roof opening panel module. (Figure 3) 8. Repeat procedure on opposite side. 9. Install headliner following WSM, Section 501-05. Parts Block 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 072006A 2006-2007 Built Before 1.9 Hrs. 3/27/2007 With Roof Opening Panel And Safety Canopy: Install The Updated Drain Tubes Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Drain: > 07-20-6 > Oct > 07 > Body - Water Leak In The Headliner/Dome Lamp Area > Page 8860 Following Service Procedure, Includes Time To Remove And Install Headliner And DVD Player If Equipped (Do Not Use With 51916A, 51916B, 51916AZV, 51916BZV) DEALER CODING CONDITION BASIC PART NO. CODE 78502C53 12 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 ROOF OPENING PANEL FRAME Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Page 8864 Part 2 Exploded Views Removal and Installation NOTE: The roof opening panel motor must be initialized when repairs are carried out on any part of the roof opening panel system, including: whenever the roof opening panel motor has been removed from the roof opening panel system, the roof opening panel glass has been removed from the roof opening panel system, the roof opening panel assembly has been removed from the vehicle, a new roof opening panel motor has been installed, a new roof opening panel glass has been installed or a new roof opening panel assembly has been installed. Refer to Roof Opening Panel Motor Initialization. See: Service and Repair/Procedures/Roof Opening Panel Motor Initialization 1. Remove the headliner. 2. Remove the 2 retaining screws and the upper console bracket. 3. Disconnect the roof opening panel motor electrical connector. 4. Disconnect the 4 roof opening panel drain hoses from the corners of the roof opening panel frame. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Page 8865 5. Remove the entertainment center support bracket (if equipped). - Remove the 7 bolts. - Remove the support bracket. CAUTION: To avoid damage to the roof opening panel frame, be sure to support the roof opening panel frame when removing the frame bolts. 6. Remove the 10 roof opening panel frame bolts. - To install, tighten to 6 Nm (53 lb-in). 7. Remove the roof opening panel frame. 8. To install, reverse the removal procedure. - Initialize the roof opening panel motor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations View 151-26 (Roof) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations > Page 8869 C921 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel Glass Sunroof / Moonroof Panel: Service and Repair Roof Opening Panel Glass ROOF OPENING PANEL GLASS Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel Glass > Page 8874 Part 2 Exploded Views Removal and Installation NOTE: The roof opening panel motor must be initialized when repairs are carried out on any part of the roof opening panel system, including: whenever the roof opening panel motor has been removed from the roof opening panel system, the roof opening panel glass has been removed from the roof opening panel system, the roof opening panel assembly has been removed from the vehicle, a new roof opening panel motor has been installed, a new roof opening panel glass has been installed or a new roof opening panel assembly has been installed. Refer to Roof Opening Panel Motor Initialization. See: Service and Repair/Procedures/Roof Opening Panel Motor Initialization 1. Open the roof opening panel to the VENT position. 2. Remove the 4 roof opening panel glass screws. - To install, tighten to 4 Nm (35 lb-in). 3. From the outside of the vehicle, remove the roof opening panel glass assembly. 4. To install, reverse the removal procedure. - If installing a new roof opening panel glass seal, use care around the corners to make sure of a correct seal to the roof opening panel glass. - Check for correct alignment of the roof opening panel. - Initialize the roof opening panel motor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel Glass > Page 8875 Sunroof / Moonroof Panel: Service and Repair Roof Opening Panel Shield ROOF OPENING PANEL SHIELD Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel Glass > Page 8876 Part 2 Exploded Views Removal and Installation 1. Remove the roof opening panel glass. 2. Remove the trough. - Pull the trough assembly arms outward to release the trough assembly guide arm pins from the roof opening panel frame to remove. 3. Remove the air deflector. - Remove the 4 screws. To install, tighten to 1 Nm (9 lb-in). - Remove the air deflector. 4. Slide the roof opening panel shield forward halfway. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel Glass > Page 8877 5. Disengage the roof opening panel shield 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 guide feet. 6. Slide the roof opening panel shield forward and release the rear guide feet. 7. NOTE: The roof opening panel shield guide feet can be serviced separately from the roof opening panel shield. If necessary, new roof opening panel shield guide feet may be installed at this time. 8. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations View 151-19 (Driver Seat) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 8883 Memory Positioning Module: Diagrams C341A C341B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 8884 C341C Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 8885 Memory Positioning Module: Description and Operation Memory Adjustable Pedal Operation The adjustable pedals with memory feature is controlled by using the memory switches or the remote keyless entry (RKE) transmitter. The exterior mirror and power driver seat positions are also stored and recalled with the power adjustable pedal positions. The system can store 3 memory settings. Driver Seat Module (DSM) The DSM controls the memory adjustable pedals. The DSM constantly monitors the systems under its control and records concerns in the form of diagnostic trouble codes (DTCs). A DTC can be retrieved with the scan tool through the data link connector (DLC). Memory Adjustable Pedal Operation The adjustable pedals with memory feature is controlled by using the memory switches or the remote keyless entry (RKE) transmitter. The exterior mirror and power driver seat positions are also stored and recalled with the power adjustable pedal positions. The system can store 3 memory settings. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Belt Tower Position Sensor > Component Information > Description and Operation Seat Belt Tower Position Sensor: Description and Operation SEAT TRACK POSITION SENSOR The seat track position sensor is a Hall-effect sensor located on the driver seat track. The seat track position sensor informs the RCM of the driver seat position. Based on programmed limits, the seat track position sensor will inform the RCM of the driver seat position. The RCM uses this information in determining the deployment rate of the dual-stage driver air bag module. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 8892 C2094 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third Row Folding Seat Motor, Left View 151-15 (Left Rear, (1 0f 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third Row Folding Seat Motor, Left > Page 8897 View 151-18 (Right Rear, (2 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third Row Folding Seat Motor, Left > Page 8898 View 151-19 (Driver Seat) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third Row Folding Seat Motor, Left > Page 8899 View 151-20 (Passenger Seat) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third Row Folding Seat Motor, Left > Page 8900 View 151-19 (Driver Seat) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver Seat Recliner Motor C3187 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver Seat Recliner Motor > Page 8903 C3015 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver Seat Recliner Motor > Page 8904 Power Seat Motor: Diagrams Power Seat Motor Assembly, Left C353 C357 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver Seat Recliner Motor > Page 8905 C4181 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver Seat Recliner Motor > Page 8906 C4182 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Seat Recliner Motor Power Seat Motor: Service and Repair Seat Recliner Motor SEAT RECLINER MOTOR Special Tool(s) Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Seat Recliner Motor > Page 8909 Front Seat Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Seat Recliner Motor > Page 8910 Front Seat Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Seat Recliner Motor > Page 8911 Driver Seat Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Seat Recliner Motor > Page 8912 Driver Seat Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Seat Recliner Motor > Page 8913 Passenger Seat Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Seat Recliner Motor > Page 8914 Passenger Seat Cushion (Part 2) Exploded View Removal WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an airbag module. This will reduce the risk of injury in the event of an accidental deployment. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - 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. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Remove the front seat and depower the supplemental restraint system (SRS). 2. Remove the front seat backrest. 3. Remove the plastic rivets attaching the backrest trim cover to the inboard and outboard recliners. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Seat Recliner Motor > Page 8915 4. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Release the backrest trim cover lower J-clip, hook-and-loop strips and invert the trim cover to the first row of hog rings. 5. Remove the one-way push clip on the side of the inboard power recliner. Slide the recliner shaft out from the outboard side of the seat enough to clear the inboard recliner and power recline motor. 6. Disconnect the electrical connector, remove the screw and the power recline motor. Installation 1. NOTE: The recliners are synchronized. Do not rotate the recliner shaft until completely installed. Install the recliner motor. 1. Position the recliner shaft through the recliner motor and inboard recliner. 2. Install a new one-way push clip onto the recliner shaft at the inboard power recliner. 3. Turn the recliner motor so the recliner motor mounting hole lines up with the screw hole in the inboard power recliner. 4. Install the recliner motor bolt. 5. Connect the recliner motor electrical connector. 2. Roll the backrest trim cover down, attach the hook-and-loop strips and connect the backrest trim cover lower J-clip. 3. Position the backrest trim cover to the inboard and outboard recliners and install the plastic rivets. 4. Install the front seat backrest. 5. Install the front seat and repower the SRS. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Seat Recliner Motor > Page 8916 Power Seat Motor: Service and Repair Power-Fold Seat Motor - Third Row POWER-FOLD SEAT MOTOR - THIRD ROW Removal and Installation NOTE: The power-fold seat motor is serviced with the latch bracket. LH or RH motors 1. Position the backrest with the working motor in the opposite position of the backrest with the motor that is not working. 2. Remove the third row seat from the vehicle. 3. Remove 2 latch-to-floor mounting bracket nuts. - To install, tighten to 22 Nm (16 lb-ft). LH motor 4. From under the RH seat, remove the 2 cushion pivot link assembly-to-cushion frame nuts and remove the RH 50 percent seat from the floor mounting bracket. To install, tighten to 22 Nm (16 lb-ft). Motor being serviced 5. Remove the latch-to-cushion frame bolt. - To install, tighten to 25 Nm (18 lb-ft). 6. Remove 2 bolts and the latch cover. 7. Release the backrest trim cover lower J-clip on the side with the motor being serviced. 8. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Release the backrest trim cover side J-clips, hook-and-loop strips and invert the trim cover to expose the 2 latch-to-backrest frame bolts on the side with the motor being serviced. 9. Remove the 2 latch-to-backrest frame bolts and remove the latch with motor. - To install, tighten to 25 Nm (18 lb-ft). LH motor 10. Remove the safety belt buckle assembly-to-latch nut and remove the safety belt buckle assembly. - To install, tighten to 75 Nm (55 lb-ft). LH or RH motors 11. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Locations View 151-15 (Left Rear, (1 0f 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Diagrams > Third Row Folding Seat Relay, Left C4183 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Diagrams > Third Row Folding Seat Relay, Left > Page 8922 C4184 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 8925 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left/Right View 151-16 (Left Rear, (2 0f 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left/Right > Page 8930 View 151-19 (Driver Seat) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left/Right > Page 8931 View 151-20 (Passenger Seat) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left Power Seat Switch: Diagrams Power Seat Switch, Left C352 C3016 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left > Page 8934 C355 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left > Page 8935 C4179 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left > Page 8936 C4180 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left > Page 8939 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left > Page 8940 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Page 8941 Power Seat Switch: Service and Repair MEMORY SET SWITCH Removal and Installation 1. Position the gear selector to NEUTRAL. 2. Remove the console trim ring. 3. Open the center console door, remove the 2 screws and pull up on the console finish panel to release the retainers. 4. Disconnect the power point electrical connector and remove the console finish panel. 5. Pull out to release the retainers and separate the instrument panel center lower RH and LH finish panels. 6. Pull out to release the retainers and separate the instrument panel center finish panel. 7. Disconnect the electrical connector, release the 4 tabs and remove the memory SET switch. 8. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > Customer Interest for Seat Back: > 07-7-3 > Apr > 07 > Interior - Front Seat Manual Lumbar Inoperative Seat Back: Customer Interest Interior - Front Seat Manual Lumbar Inoperative TSB 07-7-3 04/16/07 FRONT SEAT MANUAL LUMBAR INOPERATIVE FORD: 2006-2007 Fusion, Explorer 2007 Explorer Sport Trac MERCURY: 2006-2007 Milan This article supersedes TSB 06-21-6 and 06-20-11 to update the Service Procedure and Parts. ISSUE Some 2006-2007 Fusion and Milan vehicles built prior to 9/4/2006, Explorer 4dr/Mountaineer and 2007 Explorer Sport Trac vehicles built prior to 8/24/2006 may exhibit an inoperative adjustment of the manual lumbar assembly. ACTION Follow the service procedure outlined below to address the customer concern. SERVICE PROCEDURE Replace the lumbar strap following the lumbar procedure in the Workshop Manual (WSM), Section 501-10. DO NOT remove the cable from the lumbar adjuster. New service parts have been released and the cables should be disconnected and reconnected at the lumbar strap. Strap Replacement Procedure: 1. Release the two (2) lumbar spring clips from the backrest frame and remove the lumbar. Refer to WSM, Section 501-10 for more details. 2. Cut strap to allow removal of the cable in six (6) places while being careful not to damage the cable. (Figure 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > Customer Interest for Seat Back: > 07-7-3 > Apr > 07 > Interior - Front Seat Manual Lumbar Inoperative > Page 8950 3. Insert cable through zip tie loops and through the two (2) cable guides on the new lumbar strap. Ensure that the cable is held by the two (2) hooks. (Figure 2) 4. Snap the cable end and cable conduit end into strap. (Figure 3) Verify that both fittings are properly inserted by pushing on the fittings with the flat sur[ace of a standard screwdriver. After completing this, make sure that tabs are adequately engaged by pulling them back over the fitting with a scratch awl or small screwdriver. NOTE ON FUSION AND MILAN VEHICLES, THE CABLE DIE CAST MUST BE SNAPPED INTO THE STRAP NEAR THE BLUE ATTACHMENT WIRE AND THE OUTER CONDUIT END MUST BE SNAPPED IN TO THE STRAP NEAR THE BLACK CURVED ATTACHMENT WIRE. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > Customer Interest for Seat Back: > 07-7-3 > Apr > 07 > Interior - Front Seat Manual Lumbar Inoperative > Page 8951 5. Zip ties on both the die cast end fitting and conduit end fitting can now be pulled tight and the excess slack can be cut off. (Figures 4 and 5) 6. To install the lumbar strap assembly, reverse the removal procedure. NOTE THE LUMBAR ATTACHMENT WIRES MUST BE RUN IN AND BACK OUT OF THE LANCE TABS ON THE BACK FRAME. (Figure 6) 7. Install the front seat and repower the SRS. If a passenger seat has been serviced, do not prove out the SRS at this time. For additional information, refer to WSM, Section 501-10. 8. On Explorer and Explorer Sport Trac vehicles carry out the Occupant Classification Sensor (OCS) System Zero Weight Test and prove out the (SRS). Refer to WSM, Section 501-20B General Procedures. Parts Block 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 070703A 2006-2007 Fusion/Milan 1.5 Hrs. With Manual Lumbar Seat: Replace The Lumbar Strap, Includes Time To Depower And Repower The Supplemental Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > Customer Interest for Seat Back: > 07-7-3 > Apr > 07 > Interior - Front Seat Manual Lumbar Inoperative > Page 8952 Restraints System, Remove And Install Seat, Seat Back (Do Not Use With 64416A, 14696A, 14696B, 62900A, 63222A) 070703B 2006-2007 Explorer, 2007 1.5 Hrs. Explorer Sport Trac With Manual Lumbar Seat: Replace The Lumbar Strap, Includes Time To Depower And Repower The Supplemental Restraints System, Remove And Install Seat, Seat Back: Driver Seat (Do Not Use With 64416A 14696A, 14696B, 62900A, 63222A) 070703C 2006-2007 Explorer, 2007 1.6 Hrs. Explorer Sport Trac With Manual Lumbar Seat: Replace The Lumbar Strap, Includes Time To Depower And Repower The Supplemental Restraints System, Remove And Install Seat, Seat Back: Passenger Seat (Do Not Use With 64416A, 14696A, 14696B, 62900A, 63222A) DEALER CODING CONDITION BASIC PART NO. CODE 7865500 01 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back: > 07-7-3 > Apr > 07 > Interior - Front Seat Manual Lumbar Inoperative Seat Back: All Technical Service Bulletins Interior - Front Seat Manual Lumbar Inoperative TSB 07-7-3 04/16/07 FRONT SEAT MANUAL LUMBAR INOPERATIVE FORD: 2006-2007 Fusion, Explorer 2007 Explorer Sport Trac MERCURY: 2006-2007 Milan This article supersedes TSB 06-21-6 and 06-20-11 to update the Service Procedure and Parts. ISSUE Some 2006-2007 Fusion and Milan vehicles built prior to 9/4/2006, Explorer 4dr/Mountaineer and 2007 Explorer Sport Trac vehicles built prior to 8/24/2006 may exhibit an inoperative adjustment of the manual lumbar assembly. ACTION Follow the service procedure outlined below to address the customer concern. SERVICE PROCEDURE Replace the lumbar strap following the lumbar procedure in the Workshop Manual (WSM), Section 501-10. DO NOT remove the cable from the lumbar adjuster. New service parts have been released and the cables should be disconnected and reconnected at the lumbar strap. Strap Replacement Procedure: 1. Release the two (2) lumbar spring clips from the backrest frame and remove the lumbar. Refer to WSM, Section 501-10 for more details. 2. Cut strap to allow removal of the cable in six (6) places while being careful not to damage the cable. (Figure 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back: > 07-7-3 > Apr > 07 > Interior - Front Seat Manual Lumbar Inoperative > Page 8958 3. Insert cable through zip tie loops and through the two (2) cable guides on the new lumbar strap. Ensure that the cable is held by the two (2) hooks. (Figure 2) 4. Snap the cable end and cable conduit end into strap. (Figure 3) Verify that both fittings are properly inserted by pushing on the fittings with the flat sur[ace of a standard screwdriver. After completing this, make sure that tabs are adequately engaged by pulling them back over the fitting with a scratch awl or small screwdriver. NOTE ON FUSION AND MILAN VEHICLES, THE CABLE DIE CAST MUST BE SNAPPED INTO THE STRAP NEAR THE BLUE ATTACHMENT WIRE AND THE OUTER CONDUIT END MUST BE SNAPPED IN TO THE STRAP NEAR THE BLACK CURVED ATTACHMENT WIRE. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back: > 07-7-3 > Apr > 07 > Interior - Front Seat Manual Lumbar Inoperative > Page 8959 5. Zip ties on both the die cast end fitting and conduit end fitting can now be pulled tight and the excess slack can be cut off. (Figures 4 and 5) 6. To install the lumbar strap assembly, reverse the removal procedure. NOTE THE LUMBAR ATTACHMENT WIRES MUST BE RUN IN AND BACK OUT OF THE LANCE TABS ON THE BACK FRAME. (Figure 6) 7. Install the front seat and repower the SRS. If a passenger seat has been serviced, do not prove out the SRS at this time. For additional information, refer to WSM, Section 501-10. 8. On Explorer and Explorer Sport Trac vehicles carry out the Occupant Classification Sensor (OCS) System Zero Weight Test and prove out the (SRS). Refer to WSM, Section 501-20B General Procedures. Parts Block 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 070703A 2006-2007 Fusion/Milan 1.5 Hrs. With Manual Lumbar Seat: Replace The Lumbar Strap, Includes Time To Depower And Repower The Supplemental Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back: > 07-7-3 > Apr > 07 > Interior - Front Seat Manual Lumbar Inoperative > Page 8960 Restraints System, Remove And Install Seat, Seat Back (Do Not Use With 64416A, 14696A, 14696B, 62900A, 63222A) 070703B 2006-2007 Explorer, 2007 1.5 Hrs. Explorer Sport Trac With Manual Lumbar Seat: Replace The Lumbar Strap, Includes Time To Depower And Repower The Supplemental Restraints System, Remove And Install Seat, Seat Back: Driver Seat (Do Not Use With 64416A 14696A, 14696B, 62900A, 63222A) 070703C 2006-2007 Explorer, 2007 1.6 Hrs. Explorer Sport Trac With Manual Lumbar Seat: Replace The Lumbar Strap, Includes Time To Depower And Repower The Supplemental Restraints System, Remove And Install Seat, Seat Back: Passenger Seat (Do Not Use With 64416A, 14696A, 14696B, 62900A, 63222A) DEALER CODING CONDITION BASIC PART NO. CODE 7865500 01 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement Seat Back: Removal and Replacement Seat Backrest - Front SEAT BACKREST - FRONT Special Tool(s) Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8963 Front Seat Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8964 Front Seat Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8965 Driver Seat Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8966 Driver Seat Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8967 Passenger Seat Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8968 Passenger Seat Cushion (Part 2) Exploded View Removal and Installation WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an airbag module. This will reduce the risk of injury in the event of an accidental deployment. - To reduce the risk of personal injury, do not use any memory saver devices. - 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. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - 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. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Driver seat shown, passenger seat similar. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8969 All seats 1. Remove the front seat and depower the supplemental restraint system (SRS). 2. Remove the cushion side shield. 1. If equipped, remove the clip and manual recline handle. 2. If equipped, pull and remove the manual lumbar control knob. - Make sure the lumbar is completely relaxed before removing the handle. 3. Remove the scrivet. 4. Release the cushion side shield front clip. 5. From under the cushion side shield, release the 3 hook retainers. 6. Pull out on the cushion side shield at the back and release the pin-type retainer. 7. Separate the cushion trim cover elastic strap from the cushion side shield. - If equipped with a manual seat track, remove the cushion side shield. 8. If equipped with power seats, remove the seat control switch knob and separate the seat control switch from the cushion side shield. - Remove the cushion side shield. 3. Release the cushion trim cover rear J-clips. 1. Release the cushion trim cover rear inboard J-clip from the inboard recliner. 2. For a driver seat or passenger seat equipped with heat, release the cushion trim cover rear J-clips. 4. Release the cushion trim cover inboard J-clip. 5. Remove the safety belt buckle and pretensioner electrical connector cover. 6. Remove the 2 safety belt buckle and pretensioner nuts. - To install, tighten to 36 Nm (27 lb-ft). 7. Disconnect the safety belt buckle and pretensioner electrical connector and safety belt buckle switch electrical connector. - Remove the safety belt buckle and pretensioner. Seat with manual lumbar 8. Release the cushion trim cover front J-clip. Raise the cushion foam pad and release the lumbar cable pin-type retainer. 9. Remove the 2 screws and separate the manual lumbar control from the cushion frame. 10. Remove the cable from the manual lumbar control. Driver seat with power recline Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8970 11. Disconnect the backrest power feed electrical connector and route out the wire harness. - Release any wire harness retainers. Passenger seat with heat 12. Disconnect the backrest heated seat mat electrical connector and route out the wire harness. - Release any wire harness retainers. All seats 13. Release the pin-type retainers, disconnect and route out the side air bag module electrical connector and wire harness. 14. NOTE: Driver seat shown, passenger seat similar. Release the side air bag wire harness pin-type retainers across the back of the cushion frame. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8971 15. Remove the 4 recliner-to-cushion frame bolts and remove the backrest assembly. - Route out the manual lumbar cable and any wire harnesses (if equipped). - To install, tighten to 55 Nm (41 lb-ft). 16. To install, reverse the removal procedure. 17. Install the front seat and repower the SRS. If a passenger seat has been serviced, do not prove out the SRS at this time. Passenger seat 18. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. Seat Backrest - Second Row, 40 Percent E-Z Entry SEAT BACKREST - SECOND ROW, 40 PERCENT E-Z ENTRY Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8972 Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8973 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8974 Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Second Row, 60 Percent E-Z Entry Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8975 Second Row, 40 Percent E-Z Entry Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8976 Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8977 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8978 Second Row, Bucket, Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8979 Second Row, Bucket, Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8980 Second Row, Bucket, Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8981 Second Row, 60 Percent Bench, Backrest (Part 1) Second Row, 60 Percent Bench, Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8982 Second Row, 60 Percent Bench, Cushion (Part 1) Second Row, 60 Percent Bench, Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8983 Second Row, 40 Percent Bench, Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8984 Second Row, 40 Percent Bench, Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8985 Second Row, 40 Percent Bench, Cushion Exploded View Removal 1. Remove the second row, 40 percent E-Z entry seat from the vehicle. 2. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Release the backrest trim cover lower J-clip, hook-and-loop strips and partially invert the backrest trim cover to expose the 2 inboard and 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8986 outboard recliner-to-backrest frame bolts. 3. Separate the kneeling mechanism release handle from the backrest frame. - Release the 3 kneeling mechanism release handle clips and separate from the backrest frame. Pull the kneeling mechanism release handle and cable back through the backrest frame. Separating the kneeling mechanism release handle from the backrest frame can also be done by going between the backrest foam pad and backrest frame. Release the top and side clips and push out separating the kneeling mechanism release handle from the backrest frame. 4. Release the kneeling mechanism cable from the backrest frame. 5. Remove the 2 inboard and 2 outboard recliner-to-backrest frame bolts and remove the backrest assembly. Installation 1. Remove 3 screws, recliner handle and outboard recliner outer cover. 2. Remove 2 screws and the inboard recliner outer cover. 3. WARNING: The recliner(s) are spring-loaded. Use care when seat back frame is removed and releasing the recliners from a backrest upright position. The recliner upper arms will fold with significant speed/force. Failure to follow this instruction may result in personal injury. Position the inboard recliner pin to the recliner stop. The recliner pin must contact the inboard recliner outer plate (stop). 4. WARNING: The recliner(s) are spring-loaded. Use care when seat back frame is removed and releasing the recliners from a backrest upright position. The recliner upper arms will fold with significant speed/force. Failure to follow this instruction may result in personal injury. NOTE: If the latch feet are not locked around the strikers on the mounting plate, the recliners will not lock in position. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8987 - If the inboard recliner is not positioned to the recliner stop (or any upright position), when the outboard recliner is positioned to the recliner stop and the release strap is let go of, the recliners will not lock in place. Pull the release strap at the outboard recliner and position the outboard recliner pin to contact the recliner stop. Let go of the release strap and the inboard and outboard recliners will lock in place. Each recliner pin must contact the recliner outer plate (stop). 5. Position the backrest assembly to the inboard and outboard recliners and hand start the 2 inboard and 2 outboard recliner-to-backrest frame bolts. 6. CAUTION: The recliner-to-backrest frame bolts must be tightened in sequence or recliner latches that do not lock in place or binding may occur. Install the recliner-to-backrest frame bolts in the following sequence: 1. Install the inboard recliner-to-backrest frame upper bolt. - Tighten to 55 Nm (41 lb-ft). 2. Install the inboard recliner-to-backrest frame lower bolt. - Tighten to 55 Nm (41 lb-ft). 3. Install the outboard recliner-to-backrest frame upper bolt. - Tighten to 55 Nm (41 lb-ft). 4. Install the outboard recliner-to-backrest frame lower bolt. - Tighten to 55 Nm (41 lb-ft). 7. Position the kneeling mechanism release handle and cable back through the backrest frame and backrest trim cover openings. - Attach the kneeling mechanism release cable to the backrest frame. 8. Roll the backrest trim cover down, attach the hook-and-loop strips and connect the backrest trim cover lower J-clip. 9. Position the kneeling mechanism release handle to the backrest opening and push in, engaging the clips. 10. Route the outboard recliner release strap before installing the outboard recliner outer cover. 11. Install the outboard recliner outer cover. - Position the outboard recliner outer cover. - Route the release strap through the cover. - Install the 2 screws. - Install the recliner handle. - Install the screw. 12. Position the inboard recliner outer cover and install the 2 screws. 13. Install the second row, 40 percent E-Z entry seat into the vehicle. 14. Cycle the backrest down and then back to the upright position. Make sure the inboard and outboard recliners simultaneously and securely lock in the upright position. Seat Backrest - Second Row, 60 Percent, E-Z Entry SEAT BACKREST - SECOND ROW, 60 PERCENT, E-Z ENTRY Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8988 Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8989 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8990 Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Second Row, 60 Percent E-Z Entry Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8991 Second Row, 40 Percent E-Z Entry Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8992 Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8993 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8994 Second Row, Bucket, Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8995 Second Row, Bucket, Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8996 Second Row, Bucket, Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8997 Second Row, 60 Percent Bench, Backrest (Part 1) Second Row, 60 Percent Bench, Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8998 Second Row, 60 Percent Bench, Cushion (Part 1) Second Row, 60 Percent Bench, Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 8999 Second Row, 40 Percent Bench, Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9000 Second Row, 40 Percent Bench, Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9001 Second Row, 40 Percent Bench, Cushion Exploded View Removal 1. Remove the second row, 60 percent E-Z entry seat from the vehicle. 2. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Release the backrest trim cover lower J-clip, hook-and-loop strips and partially invert the backrest trim cover to expose the 2 inboard and 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9002 outboard recliner-to-backrest frame bolts. 3. Separate the kneeling mechanism release handle from the backrest frame. - Release the 3 kneeling mechanism release handle clips and separate from the backrest frame. Pull the kneeling mechanism release handle and cable back through the backrest frame. Separating the kneeling mechanism release handle from the backrest frame can also be done by going between the backrest foam pad and backrest frame. Release the top and side clips and push out separating the kneeling mechanism release handle from the backrest frame. 4. Release the kneeling mechanism cable from the backrest frame. 5. Remove 2 screws and the inboard recliner outer cover. 6. Remove the safety belt anchor bolt and separate the safety belt anchor from the inboard recliner. 7. Remove the 2 inboard and 2 outboard recliner-to-backrest frame bolts and remove the backrest assembly. Installation 1. Remove 3 screws, recliner handle and outboard recliner outer cover. 2. WARNING: The recliner(s) are spring-loaded. Use care when seat back frame is removed and releasing the recliners from a backrest upright position. The recliner upper arms will fold with significant speed/force. Failure to follow this instruction may result in personal injury. NOTE: This is a 2 person operation. - If the latch feet are not locked around the strikers on the mounting plate, the recliners will not lock in position. - If both of the recliners are not locked in place simultaneously, the recliners will not lock in position. Simultaneously pull the release strap at the outboard recliner and position the inboard and outboard recliner pins to the recliner stops. Let go of the release strap and the inboard and outboard recliners will lock in place. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9003 - Each recliner pin must contact the recliner outer plate (stop). 3. Position the backrest assembly to the inboard and outboard recliners and hand start the 2 inboard and 2 outboard recliner-to-backrest frame bolts. 4. CAUTION: The recliner-to-backrest frame bolts must be tightened in sequence or recliner latches that do not lock in place or binding may occur. Install the recliner-to-backrest frame bolts in the following sequence. 1. Install the inboard recliner-to-backrest frame upper bolt. - Tighten to 55 Nm (41 lb-ft). 2. Install the inboard recliner-to-backrest frame lower bolt. - Tighten to 55 Nm (41 lb-ft). 3. Install the outboard recliner-to-backrest frame upper bolt. - Tighten to 55 Nm (41 lb-ft). 4. Install the outboard recliner-to-backrest frame lower bolt. - Tighten to 55 Nm (41 lb-ft). 5. Position the kneeling mechanism release handle and cable back through the backrest frame and backrest trim cover openings. - Attach the kneeling mechanism release cable to the backrest frame. 6. Roll the backrest trim cover down, attach the hook-and-loop strips and connect the backrest trim cover lower J-clip. 7. Position the kneeling mechanism release handle to the backrest opening and push in, engaging the clips. 8. Route the outboard recliner release strap before installing the outboard recliner outer cover. 9. Position the outboard recliner outer cover, recliner handle and install the 3 screws. 10. CAUTION: Make sure the safety belt webbing is not twisted prior to installation. Position the safety belt anchor to the inboard recliner and install the safety belt anchor bolt. Tighten to 55 Nm (41 lb-ft). 11. Position the inboard recliner outer cover and install the 2 screws. - Make sure the kneeling mechanism release cable pivot is still positioned on the inboard recliner and the recliner pin is through the cable pivot before installing the inboard recliner outer cover. 12. Install the second row, 60 percent E-Z entry seat into the vehicle. 13. Cycle the backrest down and then back to the upright position. Make sure the inboard and outboard recliners simultaneously and securely lock in the upright position. Seat Backrest - Second Row, 40 Percent, Bench SEAT BACKREST - SECOND ROW, 40 PERCENT, BENCH Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9004 Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9005 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9006 Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Second Row, 60 Percent E-Z Entry Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9007 Second Row, 40 Percent E-Z Entry Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9008 Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9009 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9010 Second Row, Bucket, Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9011 Second Row, Bucket, Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9012 Second Row, Bucket, Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9013 Second Row, 60 Percent Bench, Backrest (Part 1) Second Row, 60 Percent Bench, Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9014 Second Row, 60 Percent Bench, Cushion (Part 1) Second Row, 60 Percent Bench, Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9015 Second Row, 40 Percent Bench, Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9016 Second Row, 40 Percent Bench, Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9017 Second Row, 40 Percent Bench, Cushion Exploded View Removal 1. Release the seat backrest J-clip. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9018 2. Remove all the staples holding the backrest trim cover to the backrest support panel. 3. Invert the seat backrest trim cover and foam pad to access the latch cover screws. 4. Remove the 4 screws and the 2 covers. Detach the seat backrest material attachment from both of the latch covers. 5. Remove the 2 backrest support panel lower screws and detach the latch cable. Position the cable out from between the backrest frame and backrest support panel. 6. Remove the 4 backrest pivot bolts. 7. Remove the 40 percent backrest. Installation 1. Position the backrest to the latch. The cable is to be routed in front of the spring. 2. CAUTION: The cable is to move freely after assembly. NOTE: When installing the backrest to the cushion, make sure the latch cover does not come in contact with the latch cable conduit or end fitting. The cable is to pass between the backrest frame and the backrest support at the 2 points shown. 3. Install the 4 backrest pivot bolts. - Tighten to 40 Nm (30 lb-ft). 4. Install the 2 backrest support panel lower screws. 5. CAUTION: When installing the backrest to the cushion, make sure the latch cover does not come in contact with the latch cable conduit or end fitting. Position the 2 covers and install the 4 screws. Attach the material attachments to both of the latch covers. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9019 6. Roll the seat backrest trim cover and foam pad back down into position. 7. Position the trim cover and install staples in the backrest support panel. 8. Attach the seat backrest J-clip. Seat Backrest - Second Row, 60 Percent, Bench SEAT BACKREST - SECOND ROW, 60 PERCENT, BENCH Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9020 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9021 Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Second Row, 60 Percent E-Z Entry Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9022 Second Row, 40 Percent E-Z Entry Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9023 Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9024 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9025 Second Row, Bucket, Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9026 Second Row, Bucket, Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9027 Second Row, Bucket, Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9028 Second Row, 60 Percent Bench, Backrest (Part 1) Second Row, 60 Percent Bench, Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9029 Second Row, 60 Percent Bench, Cushion (Part 1) Second Row, 60 Percent Bench, Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9030 Second Row, 40 Percent Bench, Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9031 Second Row, 40 Percent Bench, Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9032 Second Row, 40 Percent Bench, Cushion Exploded View Removal 1. Remove the safety belt anchor bolt. 2. Release the seat backrest J-clip. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9033 3. Remove all the staples holding the backrest trim cover to the backrest support panel. 4. Invert the seat backrest trim cover and reposition the foam pad to access the latch cover screws and latch cable. 5. Remove the 4 screws and the 2 covers. Detach the seat backrest material attachment from both of the latch covers. 6. Remove the 2 backrest support panel lower screws and detach the latch cable. Position the cable out from between the backrest frame and backrest support panel. 7. Remove the outboard upper pivot latch bolt. 8. Remove the 4 backrest pivot bolts. 9. Remove the 60 percent backrest. Installation 1. Position the backrest to the latch. The cable is to be routed in front of the spring. 2. CAUTION: The cable is to move freely after assembly. The cable is to pass between the backrest frame and the backrest support at the 2 points shown. 3. Install the 4 backrest pivot bolts. - Tighten to 40 Nm (30 lb-ft). 4. Install the outboard pivot latch bolt. - Tighten to 40 Nm (30 lb-ft). 5. Install the 2 backrest support panel lower screws. 6. Attach the material to both of the latch covers. Position the 2 covers and install the 4 screws. 7. Roll the seat backrest trim cover and foam pad back down into position. 8. Position the trim cover and install staples in the backrest support panel. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9034 9. Attach the seat backrest J-clip. 10. Position the safety belt anchor and install the bolt. - Tighten to 75 Nm (55 lb-ft). Seat Backrest - Second Row, Bucket SEAT BACKREST - SECOND ROW, BUCKET Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9035 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9036 Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Second Row, 60 Percent E-Z Entry Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9037 Second Row, 40 Percent E-Z Entry Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9038 Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9039 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9040 Second Row, Bucket, Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9041 Second Row, Bucket, Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9042 Second Row, Bucket, Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9043 Second Row, 60 Percent Bench, Backrest (Part 1) Second Row, 60 Percent Bench, Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9044 Second Row, 60 Percent Bench, Cushion (Part 1) Second Row, 60 Percent Bench, Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9045 Second Row, 40 Percent Bench, Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9046 Second Row, 40 Percent Bench, Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9047 Second Row, 40 Percent Bench, Cushion Exploded View Removal and Installation 1. Release all of the seat backrest J-clips. Slightly raise the backrest trim cover. 2. Remove all of the staples in the backrest trim cover. 3. Pull the seat backrest material up and remove the 4 backrest bolts. Remove the backrest assembly. - To install, tighten to 23 Nm (17 lb-ft). 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9048 Seat Backrest - Third Row SEAT BACKREST - THIRD ROW Third Row Seat Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9049 Third Row Seat Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9050 Third Row Seat Cushion (Part 2) Exploded View Removal and Installation All seats 1. Fold the backrest not being serviced down. 2. Remove 2 bolts and the hinge cover on the backrest being serviced. 3. Remove 2 bolts and the latch cover on the backrest being serviced. 4. Release the backrest trim cover lower J-clip on the backrest being serviced. 5. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Release the backrest trim cover side J-clips, hook-and-loop strips and invert the trim cover to expose the 2 hinge-to-backrest frame bolts and the 2 latch-to-backrest frame bolts on the backrest being serviced. Manual fold seats 6. Separate the cable casing from the latch and remove the cable from the latch lever on the backrest being serviced. All seats 7. Remove the 2 hinge-to-backrest frame bolts and the 2 latch-to-backrest frame bolts and remove the backrest. - To install, tighten to 25 Nm (18 lb-ft). 8. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9051 Seat Back: Overhaul Seat Backrest - Front SEAT BACKREST - FRONT Special Tool(s) Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9052 Front Seat Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9053 Front Seat Backrest (Part 2) 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. - 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 afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Side air bag modules with damaged covers must be replaced. - Front seat back trim covers installed on seats equipped with side air bags cannot be repaired, they are to be replaced. Cleaning is permissible. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a side air bag deployment took place a new backrest foam pad, backrest trim cover and side air bag module must be installed. A new backrest frame should be installed if necessary. - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the restraint control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The supplemental restraint system (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. - The manual recliners and power recliners are serviced as part of the backrest frame. All seats 1. Remove the front seat and depower the supplemental restraint system (SRS). 2. Remove the front seat backrest. 3. Remove the head restraint. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9054 1. Using an appropriate tool, push in the hole while lifting up and release the head restraint from the head restraint guide. 2. Push in on the head restraint guide release tab and remove the head restraint. 4. Remove the plastic rivets attaching the backrest trim cover to the inboard and outboard recliners. 5. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Release the backrest trim cover lower J-clip, hook-and-loop strips and invert the trim cover to the first row of hog rings. 6. Remove the first row of hog rings. 7. Release the hook-and-loop strips, invert the trim cover and remove the second row of hog rings. 8. NOTE: The head restraint guides are not interchangeable. Note location for installation. Reach up into the backrest and squeeze the head restraint guide ends together to release. Pull the 2 head restraint guides out of the backrest frame. 9. Remove the backrest trim cover. Heated seat 10. For power driver seat, disconnect the backrest heated seat mat electrical connector. - If necessary, remove the backrest heated seat mat from the backrest foam pad. All seats 11. Separate the backrest foam pad from the backrest frame. 12. NOTE: Note the side air bag module wire harness routing for assembly. Release the side air bag module wire harness pin-type retainers, remove the bolts and the side air bag module with wire harness. Seat with manual lumbar 13. Release the 2 manual lumbar spring clips from the backrest frame and remove the manual lumbar. Seat with power lumbar 14. Remove the power lumbar adjust assembly. 1. Disconnect the power lumbar adjust assembly motor electrical connector. 2. Release the 2 power lumbar adjust assembly lower pin-type retainers to the backrest frame. 3. Slide the power lumbar adjust assembly rods out of the backrest frame at the top and remove the power lumbar adjust assembly. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9055 Seat with power recline 15. Remove a one-way push clip from the recliner shaft and remove the recliner shaft. 16. Disconnect the electrical connector, remove the screw and the power recline motor. Assembly Seat with power recline 1. NOTE: The recliners are synchronized. Do not rotate the recliner shaft until completely installed. Install the recliner motor. Position the recliner shaft through the inboard power recliner, power recline motor and outboard recliner. Slight turning of the recliner shaft may be necessary. - Install a new one-way push clip at each end of the recliner shaft. - Turn the power recline motor so the mounting hole lines up with the bolt hole in the inboard power recliner. - Install the power recline motor bolt. - Connect the power recline motor electrical connector. Seat with power lumbar 2. Install the power lumbar adjust assembly. - Slide the power lumbar adjust assembly rods into the backrest frame holes at the top. - Attach the 2 power lumbar adjust assembly lower pin-type retainers to the backrest frame. - Connect the power lumbar adjust assembly motor electrical connector. Seat with manual lumbar 3. Attach the 2 manual lumbar spring clips to the backrest frame. All seats 4. WARNING: - Before installing the side air bag module, check it for damage and foreign objects. If the air bag module is damaged, install a new one. 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. - Inspect the mounting surfaces of the side air bag module and the seat back frame 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 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. CAUTION: Make sure the side air bag module wiring harness is not pinched between the side air bag module and the mounting bracket. Align the holes of the side air bag module bracket to the U-nuts on the backrest frame. Install new U-nuts if installing a new side air bag module. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9056 5. Slide the side air bag module onto the backrest frame so the bracket hook wraps around the backrest frame. 6. Install the side air bag module bolts, route the wire harness as noted during disassembly and install the side air bag module wire harness pin-type retainers. Tighten to 10 Nm (89 lb-in). Heated seat 7. If necessary, install the backrest heated seat mat. - For driver seats with power recline, connect the backrest heated seat mat electrical connector. All seats 8. Position the backrest foam pad around the backrest frame. 9. Position the backrest trim cover to the backrest frame and foam pad. 10. Roll the backrest trim cover down, attach the hook-and-loop strips and install the second row of hog rings. 11. Roll the backrest trim cover down, attach the hook-and-loop strips and install the first row of hog rings. 12. Roll the backrest trim cover down, attach the hook-and-loop strips and connect the backrest trim cover lower J-clip. 13. Position the backrest trim cover to the inboard and outboard recliners and install the plastic rivets. 14. NOTE: The head restraint guides are not interchangeable. Install the head restraint guides. 15. Install the head restraint. 16. Install the front seat backrest. 17. Install the front seat and repower the SRS. If a passenger seat has been serviced, do not prove out the SRS at this time. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9057 Passenger seat 18. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. Seat Backrest - Second Row, 40 Percent E-Z Entry SEAT BACKREST - SECOND ROW, 40 PERCENT E-Z ENTRY Second Row, 40 Percent E-Z Entry Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9058 Second Row, 40 Percent E-Z Entry Backrest (Part 2) Disassembly and Assembly 1. Remove the second row, 40 percent E-Z entry seat from the vehicle. 2. Remove the second row, 40 percent E-Z entry seat backrest. 3. Using an appropriate tool, push in the hole of each head restraint guide while lifting up and remove the head restraint. 4. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Release the hook-and-loop strips, invert the trim cover as high as it will go. 5. From between the backrest foam pad and the backrest frame, reach up, pinch the ends together and remove the 2 head restraint guides. 6. Remove the backrest trim cover. 7. Separate the backrest foam pad from the backrest frame. 8. To assemble, reverse the disassembly procedure. Seat Backrest - Second Row, 60 Percent, E-Z Entry SEAT BACKREST - SECOND ROW, 60 PERCENT, E-Z ENTRY Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9059 Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9060 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Disassembly 1. Remove the second row, 60 percent E-Z entry seat. 2. Remove the second row, 60 percent E-Z entry seat backrest. 3. Using an appropriate tool, push in the hole of each head restraint guide while lifting up and remove the head restraint. 4. Remove the safety belt bezel. 5. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Release the hook-and-loop strips and invert the trim cover as high as it will go. 6. From between the backrest foam pad and the backrest frame, reach up pinch the ends together and remove the 2 head restraint guides. 7. Route out the safety belt and remove the backrest trim cover. 8. Remove the backrest foam pad from the backrest frame. 9. Remove the safety belt retractor cover. - Remove the pin-type retainer. - Release the rear of the safety belt retractor cover from the backrest frame. - Route out the safety belt and remove the safety belt retractor cover. 10. Remove the bolt, safety belt retractor and insulator. - To install, tighten to 75 Nm (55 lb-ft). - If necessary, remove the safety belt retractor insulator. 11. To assemble, reverse the disassembly procedure. Seat Backrest - Second Row, 40 Percent, Bench SEAT BACKREST - SECOND ROW, 40 PERCENT, BENCH Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9061 Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9062 Disassembly and Assembly 1. Remove the second row, 40 percent seat. 2. Remove the second row, 40 percent seat backrest. 3. Remove the screw and the release handle. 4. Remove the 3 screws and the latch cover. 5. Remove the bolt and the safety belt buckle. - To install, tighten to 55 Nm (41 lb-ft). 6. Remove the head restraint. 7. NOTE: - The inboard and outboard head restraint sleeves are not interchangeable. - The head restraint sleeves incorporate an alignment tab that must face forward when installed. Squeeze together the tip of the head restraint sleeve and pull the sleeve out of the frame tube. 8. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Separate the hook-and-loop fasteners. Remove the seat backrest trim cover. 9. Remove the backrest foam pad. 10. Remove the 2 outboard lower latch bolts. - To install, tighten to 40 Nm (30 lb-ft). 11. Remove the 2 inboard lower latch bolts. - To install, tighten to 40 Nm (30 lb-ft). 12. CAUTION: Do not detach the latch cable from the seat latches. The latch assembly is synchronized; if disassembled, the latch assembly may not operate correctly. Remove the latch assembly. Do not separate or disassemble the latch assembly components. 13. To assemble, reverse the disassembly procedure. Seat Backrest - Second Row, 60 Percent, Bench SEAT BACKREST - SECOND ROW, 60 PERCENT, BENCH Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9063 Disassembly and Assembly 1. Remove the second row, 60 percent seat. 2. Remove the second row, 60 percent seat backrest. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9064 3. Using an appropriate tool, push in the hole of each head restraint guide while lifting up and remove the head restraint. 4. NOTE: - The inboard and outboard head restraint sleeves are not interchangeable. - The head restraint sleeves incorporate an alignment tab that must face forward when installed. Squeeze together the tip of the head restraint sleeve and pull the sleeve out of the frame tube. 5. Pull at the bottom and remove the safety belt guide cover. 6. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Separate the hook-and-loop fasteners, invert the backrest trim cover and remove the hog rings. Remove the backrest trim cover. Feed the safety belt out through the backrest trim cover. 7. Remove the backrest foam pad. 8. Remove the safety belt retractor cover. 9. Remove the bolt and the safety belt retractor. - To install, tighten to 75 Nm (55 lb-ft). 10. To assemble, reverse the disassembly procedure. Seat Backrest - Second Row, Bucket SEAT BACKREST - SECOND ROW, BUCKET Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9065 Disassembly and Assembly 1. Remove the second row, 40 percent bucket seat backrest. 2. Remove the head restraint. 3. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Separate the backrest trim cover hook-and-loop fasteners, remove 2 rows of hog rings and invert the backrest trim cover as high as it will go. 4. NOTE: - The inboard and outboard head restraint sleeves are not interchangeable. - The head restraint sleeves incorporate an alignment tab that must face forward when installed. Squeeze together the tip of the head restraint sleeve and pull the sleeve out of the frame tube. 5. Remove the backrest trim cover. 6. Remove the backrest foam pad from the backrest frame. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9066 7. To assemble, reverse the disassembly procedure. Seat Backrest - Third Row SEAT BACKREST - THIRD ROW Third Row Seat Backrest Disassembly and Assembly All seats 1. Remove the seat backrest. 2. Release the backrest trim cover J-clip at the top of the trim cover by the head restraint. - Pull the head restraint release strap through the backrest trim cover. 3. Remove the 2 head restraint-to-backrest frame bolts and remove the head restraint. - To install, tighten to 25 Nm (18 lb-ft). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 9067 Manual fold seats 4. Release the 3 backrest release handle clips and separate from the backrest. All seats 5. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Release the hook-and-loop strips, invert and remove the backrest trim cover. If equipped, route the backrest release handle and cable through the backrest trim cover. Manual fold seats 6. Route the backrest release cable out of the backrest frame and remove the backrest release handle and cable. All seats 7. Separate the backrest foam pad from the backrest frame. 8. To assemble, reverse the disassembly procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front Seat Cover: Service and Repair Seat Backrest Cover - Front SEAT BACKREST COVER - FRONT Special Tool(s) Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9072 Front Seat Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9073 Front Seat Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9074 Driver Seat Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9075 Driver Seat Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9076 Passenger Seat Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9077 Passenger Seat Cushion (Part 2) Exploded View Removal and Installation WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an airbag module. This will reduce the risk of injury in the event of an accidental deployment. - Front seat back trim covers installed on seats equipped with side air bags cannot be repaired; they are to be replaced (cleaning is permissible). - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - 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. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All seats Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9078 1. Remove the front seat and depower the supplemental restraint system (SRS). 2. Remove the front seat backrest. 3. Remove the head restraint. 1. Using an appropriate tool, push in the hole while lifting up and release the head restraint from the head restraint guide. 2. Push in on the head restraint guide release tab and remove the head restraint. 4. Remove the plastic rivets attaching the backrest trim cover to the inboard and outboard recliners. 5. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Release the backrest trim cover lower J-clip, hook-and-loop strips and invert the trim cover to the first row of hog rings. 6. Remove the first row of hog rings. 7. Release the hook-and-loop strips, invert the trim cover and remove the second row of hog rings. 8. NOTE: The head restraint guides are not interchangeable. Note location for installation. Reach up into the backrest and squeeze the head restraint guide ends together to release. Pull the 2 head restraint guides out of the backrest frame. 9. Remove the backrest trim cover. 10. To install, reverse the removal procedure. 11. Install the front seat backrest. 12. Install the front seat and repower the SRS. If a passenger seat has been serviced, do not prove out the SRS at this time. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9079 Passenger seat 13. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9080 Seat Cover: Service and Repair Seat Cushion Cover - Front SEAT CUSHION COVER - FRONT Special Tool(s) Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9081 Front Seat Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9082 Front Seat Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9083 Driver Seat Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9084 Driver Seat Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9085 Passenger Seat Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9086 Passenger Seat Cushion (Part 2) Exploded View Removal and 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - 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. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All seats 1. Remove the front seat and depower the supplemental restraint system (SRS). 2. Remove the cushion side shield. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9087 1. If equipped, remove the clip and manual recline handle. 2. If equipped, pull and remove the manual lumbar control knob. 3. Remove the scrivet. 4. Release the cushion side shield front clip. 5. From under the cushion side shield, release the 3 hook retainers. 6. Pull out on the cushion side shield at the back and release the pin-type retainer. 7. Separate the cushion trim cover elastic strap from the cushion side shield. - If equipped with a manual seat track, remove the cushion side shield. 8 If equipped with power seats, remove the seat control switch knob and separate the seat control switch from the cushion side shield. Remove the cushion side shield. 3. Release all the cushion trim cover to cushion frame retainers. 4. CAUTION: Use care when separating the cushion trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the cushion foam pad. Release the hook-and-loop strips, remove the hog rings and remove the cushion trim cover from the cushion foam pad. 5. To install, reverse the removal procedure. 6. Install the front seat and repower the SRS. If a passenger seat has been serviced, do not prove out the SRS at this time. Passenger seat 7. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9088 Seat Cover: Service and Repair Seat Backrest Cover - Second Row, 40 Percent E-Z Entry SEAT BACKREST COVER - SECOND ROW, 40 PERCENT E-Z ENTRY Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9089 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9090 Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Second Row, 60 Percent E-Z Entry Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9091 Second Row, 40 Percent E-Z Entry Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9092 Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9093 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9094 Second Row, Bucket, Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9095 Second Row, Bucket, Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9096 Second Row, Bucket, Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9097 Second Row, 60 Percent Bench, Backrest (Part 1) Second Row, 60 Percent Bench, Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9098 Second Row, 60 Percent Bench, Cushion (Part 1) Second Row, 60 Percent Bench, Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9099 Second Row, 40 Percent Bench, Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9100 Second Row, 40 Percent Bench, Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9101 Second Row, 40 Percent Bench, Cushion Exploded View Removal and Installation Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9102 1. Using an appropriate tool, push in the hole of each head restraint guide while lifting up and remove the head restraint. 2. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Release the backrest trim cover lower J-clip, hook-and-loop strips and partially invert the trim cover. 3. Separate the kneeling mechanism release handle from the backrest frame. - Release the 3 kneeling mechanism release handle clips and separate from the backrest frame. Separating the kneeling mechanism release handle from the backrest frame can also be done by going between the backrest foam pad and backrest frame. Release the top and side clips and push out, separating the kneeling mechanism release handle from the backrest frame. 4. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Release the hook-and-loop strips and invert the trim cover as high as it will go. Pull the kneeling mechanism release handle and cable through the backrest trim cover opening. 5. From between the backrest foam pad and the backrest frame, reach up, pinch the ends together and remove the head restraint guides. 6. Remove the backrest trim cover. 7. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9103 Seat Cover: Service and Repair Seat Backrest Cover - Second Row, 60 Percent, E-Z Entry SEAT BACKREST COVER - SECOND ROW, 60 PERCENT, E-Z ENTRY Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9104 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9105 Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Second Row, 60 Percent E-Z Entry Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9106 Second Row, 40 Percent E-Z Entry Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9107 Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9108 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9109 Second Row, Bucket, Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9110 Second Row, Bucket, Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9111 Second Row, Bucket, Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9112 Second Row, 60 Percent Bench, Backrest (Part 1) Second Row, 60 Percent Bench, Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9113 Second Row, 60 Percent Bench, Cushion (Part 1) Second Row, 60 Percent Bench, Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9114 Second Row, 40 Percent Bench, Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9115 Second Row, 40 Percent Bench, Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9116 Second Row, 40 Percent Bench, Cushion Exploded View Removal and Installation Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9117 1. Using an appropriate tool, push in the hole of each head restraint guide while lifting up and remove the head restraint. 2. Remove 2 screws and the inboard recliner outer cover. 3. CAUTION: Make sure the safety belt webbing is not twisted prior to installation. Remove the safety belt anchor bolt and separate safety belt anchor from the inboard recliner. To install, tighten to 55 Nm (41 lb-ft). 4. Remove the safety belt bezel. 5. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Release the backrest trim cover lower J-clip, hook-and-loop strips and partially invert the backrest trim cover. 6. Separate the kneeling mechanism release handle from the backrest frame. - Release the 3 kneeling mechanism release handle clips and separate from the backrest frame. Separating the kneeling mechanism release handle from the backrest frame can also be done by going between the backrest foam pad and backrest frame. Release the top and side clips and push out separating the kneeling mechanism release handle from the backrest frame. 7. Release the hook-and-loop strips and invert the trim cover as high as it will go. - Pull the kneeling mechanism release handle and cable through the backrest trim cover opening. 8. From between the backrest foam pad and the backrest frame, reach up, pinch the ends together and remove the 2 head restraint guides. 9. Route out the safety belt and remove the backrest trim cover. 10. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9118 Seat Cover: Service and Repair Seat Backrest Cover - Front SEAT BACKREST COVER - FRONT Special Tool(s) Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9119 Front Seat Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9120 Front Seat Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9121 Driver Seat Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9122 Driver Seat Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9123 Passenger Seat Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9124 Passenger Seat Cushion (Part 2) Exploded View Removal and Installation WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an airbag module. This will reduce the risk of injury in the event of an accidental deployment. - Front seat back trim covers installed on seats equipped with side air bags cannot be repaired; they are to be replaced (cleaning is permissible). - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - 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. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All seats Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9125 1. Remove the front seat and depower the supplemental restraint system (SRS). 2. Remove the front seat backrest. 3. Remove the head restraint. 1. Using an appropriate tool, push in the hole while lifting up and release the head restraint from the head restraint guide. 2. Push in on the head restraint guide release tab and remove the head restraint. 4. Remove the plastic rivets attaching the backrest trim cover to the inboard and outboard recliners. 5. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Release the backrest trim cover lower J-clip, hook-and-loop strips and invert the trim cover to the first row of hog rings. 6. Remove the first row of hog rings. 7. Release the hook-and-loop strips, invert the trim cover and remove the second row of hog rings. 8. NOTE: The head restraint guides are not interchangeable. Note location for installation. Reach up into the backrest and squeeze the head restraint guide ends together to release. Pull the 2 head restraint guides out of the backrest frame. 9. Remove the backrest trim cover. 10. To install, reverse the removal procedure. 11. Install the front seat backrest. 12. Install the front seat and repower the SRS. If a passenger seat has been serviced, do not prove out the SRS at this time. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9126 Passenger seat 13. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. Seat Cushion Cover - Front SEAT CUSHION COVER - FRONT Special Tool(s) Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9127 Front Seat Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9128 Front Seat Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9129 Driver Seat Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9130 Driver Seat Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9131 Passenger Seat Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9132 Passenger Seat Cushion (Part 2) Exploded View Removal and 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - 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. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All seats 1. Remove the front seat and depower the supplemental restraint system (SRS). 2. Remove the cushion side shield. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9133 1. If equipped, remove the clip and manual recline handle. 2. If equipped, pull and remove the manual lumbar control knob. 3. Remove the scrivet. 4. Release the cushion side shield front clip. 5. From under the cushion side shield, release the 3 hook retainers. 6. Pull out on the cushion side shield at the back and release the pin-type retainer. 7. Separate the cushion trim cover elastic strap from the cushion side shield. - If equipped with a manual seat track, remove the cushion side shield. 8 If equipped with power seats, remove the seat control switch knob and separate the seat control switch from the cushion side shield. Remove the cushion side shield. 3. Release all the cushion trim cover to cushion frame retainers. 4. CAUTION: Use care when separating the cushion trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the cushion foam pad. Release the hook-and-loop strips, remove the hog rings and remove the cushion trim cover from the cushion foam pad. 5. To install, reverse the removal procedure. 6. Install the front seat and repower the SRS. If a passenger seat has been serviced, do not prove out the SRS at this time. Passenger seat 7. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. Seat Backrest Cover - Second Row, 40 Percent E-Z Entry SEAT BACKREST COVER - SECOND ROW, 40 PERCENT E-Z ENTRY Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9134 Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9135 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9136 Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Second Row, 60 Percent E-Z Entry Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9137 Second Row, 40 Percent E-Z Entry Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9138 Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9139 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9140 Second Row, Bucket, Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9141 Second Row, Bucket, Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9142 Second Row, Bucket, Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9143 Second Row, 60 Percent Bench, Backrest (Part 1) Second Row, 60 Percent Bench, Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9144 Second Row, 60 Percent Bench, Cushion (Part 1) Second Row, 60 Percent Bench, Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9145 Second Row, 40 Percent Bench, Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9146 Second Row, 40 Percent Bench, Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9147 Second Row, 40 Percent Bench, Cushion Exploded View Removal and Installation Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9148 1. Using an appropriate tool, push in the hole of each head restraint guide while lifting up and remove the head restraint. 2. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Release the backrest trim cover lower J-clip, hook-and-loop strips and partially invert the trim cover. 3. Separate the kneeling mechanism release handle from the backrest frame. - Release the 3 kneeling mechanism release handle clips and separate from the backrest frame. Separating the kneeling mechanism release handle from the backrest frame can also be done by going between the backrest foam pad and backrest frame. Release the top and side clips and push out, separating the kneeling mechanism release handle from the backrest frame. 4. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Release the hook-and-loop strips and invert the trim cover as high as it will go. Pull the kneeling mechanism release handle and cable through the backrest trim cover opening. 5. From between the backrest foam pad and the backrest frame, reach up, pinch the ends together and remove the head restraint guides. 6. Remove the backrest trim cover. 7. To install, reverse the removal procedure. Seat Backrest Cover - Second Row, 60 Percent, E-Z Entry SEAT BACKREST COVER - SECOND ROW, 60 PERCENT, E-Z ENTRY Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9149 Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9150 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9151 Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Second Row, 60 Percent E-Z Entry Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9152 Second Row, 40 Percent E-Z Entry Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9153 Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9154 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9155 Second Row, Bucket, Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9156 Second Row, Bucket, Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9157 Second Row, Bucket, Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9158 Second Row, 60 Percent Bench, Backrest (Part 1) Second Row, 60 Percent Bench, Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9159 Second Row, 60 Percent Bench, Cushion (Part 1) Second Row, 60 Percent Bench, Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9160 Second Row, 40 Percent Bench, Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9161 Second Row, 40 Percent Bench, Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9162 Second Row, 40 Percent Bench, Cushion Exploded View Removal and Installation Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9163 1. Using an appropriate tool, push in the hole of each head restraint guide while lifting up and remove the head restraint. 2. Remove 2 screws and the inboard recliner outer cover. 3. CAUTION: Make sure the safety belt webbing is not twisted prior to installation. Remove the safety belt anchor bolt and separate safety belt anchor from the inboard recliner. To install, tighten to 55 Nm (41 lb-ft). 4. Remove the safety belt bezel. 5. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Release the backrest trim cover lower J-clip, hook-and-loop strips and partially invert the backrest trim cover. 6. Separate the kneeling mechanism release handle from the backrest frame. - Release the 3 kneeling mechanism release handle clips and separate from the backrest frame. Separating the kneeling mechanism release handle from the backrest frame can also be done by going between the backrest foam pad and backrest frame. Release the top and side clips and push out separating the kneeling mechanism release handle from the backrest frame. 7. Release the hook-and-loop strips and invert the trim cover as high as it will go. - Pull the kneeling mechanism release handle and cable through the backrest trim cover opening. 8. From between the backrest foam pad and the backrest frame, reach up, pinch the ends together and remove the 2 head restraint guides. 9. Route out the safety belt and remove the backrest trim cover. 10. To install, reverse the removal procedure. Seat Cushion Cover - Second Row, 40 Percent E-Z Entry SEAT CUSHION COVER - SECOND ROW, 40 PERCENT E-Z ENTRY Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9164 Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9165 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9166 Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Second Row, 60 Percent E-Z Entry Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9167 Second Row, 40 Percent E-Z Entry Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9168 Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9169 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9170 Second Row, Bucket, Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9171 Second Row, Bucket, Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9172 Second Row, Bucket, Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9173 Second Row, 60 Percent Bench, Backrest (Part 1) Second Row, 60 Percent Bench, Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9174 Second Row, 60 Percent Bench, Cushion (Part 1) Second Row, 60 Percent Bench, Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9175 Second Row, 40 Percent Bench, Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9176 Second Row, 40 Percent Bench, Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9177 Second Row, 40 Percent Bench, Cushion Exploded View Removal and Installation 1. Remove the 2 screws and the latch feet release bar. 2. Release all the cushion trim cover retainers and pin-type retainers. 3. CAUTION: Use care when separating the cushion trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the cushion foam pad. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9178 Release the hook-and-loop strips and remove the cushion trim cover from the cushion foam pad. 4. To install, reverse the removal procedure. Seat Cushion Cover - Second Row, 60 Percent, E-Z Entry SEAT CUSHION COVER - SECOND ROW, 60 PERCENT, E-Z ENTRY Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9179 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9180 Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Second Row, 60 Percent E-Z Entry Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9181 Second Row, 40 Percent E-Z Entry Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9182 Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9183 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9184 Second Row, Bucket, Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9185 Second Row, Bucket, Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9186 Second Row, Bucket, Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9187 Second Row, 60 Percent Bench, Backrest (Part 1) Second Row, 60 Percent Bench, Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9188 Second Row, 60 Percent Bench, Cushion (Part 1) Second Row, 60 Percent Bench, Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9189 Second Row, 40 Percent Bench, Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9190 Second Row, 40 Percent Bench, Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9191 Second Row, 40 Percent Bench, Cushion Exploded View Removal and Installation 1. Remove the 2 screws and the latch feet release bar. 2. Release all the cushion trim cover retainers and pin-type retainers. 3. CAUTION: Use care when separating the cushion trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the cushion foam pad. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9192 Release the hook-and-loop strips and separate the cushion trim cover from the cushion foam pad. 4. To install, reverse the removal procedure. - After installation, make sure the LATCH and safety belt buckles are accessible to the occupants. Seat Backrest Cover - Second Row, 40 Percent, Bench SEAT BACKREST COVER - SECOND ROW, 40 PERCENT, BENCH Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9193 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9194 Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Second Row, 60 Percent E-Z Entry Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9195 Second Row, 40 Percent E-Z Entry Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9196 Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9197 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9198 Second Row, Bucket, Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9199 Second Row, Bucket, Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9200 Second Row, Bucket, Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9201 Second Row, 60 Percent Bench, Backrest (Part 1) Second Row, 60 Percent Bench, Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9202 Second Row, 60 Percent Bench, Cushion (Part 1) Second Row, 60 Percent Bench, Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9203 Second Row, 40 Percent Bench, Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9204 Second Row, 40 Percent Bench, Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9205 Second Row, 40 Percent Bench, Cushion Exploded View Removal and Installation 1. Remove the head restraint. 2. Release the seat backrest J-clip. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9206 3. Remove all the staples holding the backrest trim cover to the backrest support panel. 4. Invert the seat backrest trim cover and foam pad to access the head restraint sleeve. 5. NOTE: - The inboard and outboard head restraint sleeves are not interchangeable. - The head restraint sleeves incorporate an alignment tab that must face forward when installed. Squeeze together the tip of the head restraint sleeve and pull the sleeve out of the frame tube. 6. CAUTION: Use care when separating the seat upholstery from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat backrest foam pad. Separate the hook-and-loop fasteners. Remove the seat backrest trim cover. 7. To install, reverse the removal procedure. Seat Backrest Cover - Second Row, 60 Percent, Bench SEAT BACKREST COVER - SECOND ROW, 60 PERCENT, BENCH Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9207 Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9208 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9209 Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Second Row, 60 Percent E-Z Entry Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9210 Second Row, 40 Percent E-Z Entry Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9211 Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9212 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9213 Second Row, Bucket, Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9214 Second Row, Bucket, Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9215 Second Row, Bucket, Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9216 Second Row, 60 Percent Bench, Backrest (Part 1) Second Row, 60 Percent Bench, Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9217 Second Row, 60 Percent Bench, Cushion (Part 1) Second Row, 60 Percent Bench, Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9218 Second Row, 40 Percent Bench, Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9219 Second Row, 40 Percent Bench, Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9220 Second Row, 40 Percent Bench, Cushion Exploded View Removal and Installation 1. Remove the second row, 60 percent seat. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9221 2. Using an appropriate tool, push in the hole of each head restraint guide while lifting up and remove the head restraint. 3. Remove the safety belt anchor bolt. - To install, tighten to 75 Nm (55 lb-ft). 4. Pull out at the bottom and remove the safety belt guide cover. 5. Release the backrest trim cover J-clip. 6. Remove all the staples in the backrest support panel. 7. CAUTION: Use care when separating the seat upholstery from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat backrest foam pad. Separate the hook-and-loop fasteners, invert the backrest trim cover and remove the hog rings. 8. NOTE: - The inboard and outboard head restraint sleeves are not interchangeable. - The head restraint sleeves incorporate an alignment tab that must face forward when installed. Squeeze together the tip of the head restraint sleeve and pull the sleeve out of the frame tube. 9. Separate the hook-and-loop fasteners. Remove the backrest trim cover. - Feed the safety belt out through the backrest trim cover. 10. To install, reverse the removal procedure. Seat Cushion Cover - Second Row, 40 Percent, Bench SEAT CUSHION COVER - SECOND ROW, 40 PERCENT, BENCH Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9222 Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9223 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9224 Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Second Row, 60 Percent E-Z Entry Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9225 Second Row, 40 Percent E-Z Entry Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9226 Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9227 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9228 Second Row, Bucket, Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9229 Second Row, Bucket, Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9230 Second Row, Bucket, Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9231 Second Row, 60 Percent Bench, Backrest (Part 1) Second Row, 60 Percent Bench, Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9232 Second Row, 60 Percent Bench, Cushion (Part 1) Second Row, 60 Percent Bench, Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9233 Second Row, 40 Percent Bench, Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9234 Second Row, 40 Percent Bench, Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9235 Second Row, 40 Percent Bench, Cushion Exploded View Removal and Installation 1. Remove the second row, 40 percent of 60/40 bench seat. 2. CAUTION: Use care when separating the cushion trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the cushion foam pad. Release the J-clips, separate the hook-and-loop fasteners, remove the hog rings and the cushion trim cover. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9236 3. To install, reverse the removal procedure. Seat Cushion Cover - Second Row, 60 Percent, Bench SEAT CUSHION COVER - SECOND ROW, 60 PERCENT, BENCH Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9237 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9238 Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Second Row, 60 Percent E-Z Entry Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9239 Second Row, 40 Percent E-Z Entry Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9240 Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9241 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9242 Second Row, Bucket, Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9243 Second Row, Bucket, Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9244 Second Row, Bucket, Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9245 Second Row, 60 Percent Bench, Backrest (Part 1) Second Row, 60 Percent Bench, Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9246 Second Row, 60 Percent Bench, Cushion (Part 1) Second Row, 60 Percent Bench, Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9247 Second Row, 40 Percent Bench, Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9248 Second Row, 40 Percent Bench, Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9249 Second Row, 40 Percent Bench, Cushion Exploded View Removal and Installation 1. Remove the second row, 60 percent seat. 2. CAUTION: Use care when separating the cushion trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the cushion foam pad. Release the J-clips, separate the hook-and-loop fasteners, remove the hog rings and the cushion trim cover. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9250 3. To install, reverse the removal procedure. Seat Backrest Cover - Second Row, Bucket SEAT BACKREST COVER - SECOND ROW, BUCKET Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9251 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9252 Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Second Row, 60 Percent E-Z Entry Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9253 Second Row, 40 Percent E-Z Entry Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9254 Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9255 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9256 Second Row, Bucket, Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9257 Second Row, Bucket, Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9258 Second Row, Bucket, Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9259 Second Row, 60 Percent Bench, Backrest (Part 1) Second Row, 60 Percent Bench, Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9260 Second Row, 60 Percent Bench, Cushion (Part 1) Second Row, 60 Percent Bench, Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9261 Second Row, 40 Percent Bench, Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9262 Second Row, 40 Percent Bench, Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9263 Second Row, 40 Percent Bench, Cushion Exploded View Removal and Installation 1. Remove the head restraint. 2. CAUTION: Use care when separating the seat upholstery from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat backrest foam pad. Release the backrest trim cover lower J-clip, separate the hook-and-loop fasteners, remove 2 rows of hog rings and invert the backrest trim cover Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9264 as high as it will go. 3. NOTE: - The inboard and outboard head restraint sleeves are not interchangeable. - The head restraint sleeves incorporate an alignment tab that must face forward when installed. Squeeze together the tip of the head restraint sleeve and pull the sleeve out of the frame tube. 4. Remove the seat backrest trim cover. 5. To install, reverse the removal procedure. Seat Cushion Cover - Second Row, Bucket SEAT CUSHION COVER - SECOND ROW, BUCKET Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9265 Second Row, 60 Percent E-Z Entry Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9266 Second Row, 60 Percent E-Z Entry Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9267 Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Second Row, 60 Percent E-Z Entry Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9268 Second Row, 40 Percent E-Z Entry Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9269 Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9270 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9271 Second Row, Bucket, Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9272 Second Row, Bucket, Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9273 Second Row, Bucket, Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9274 Second Row, 60 Percent Bench, Backrest (Part 1) Second Row, 60 Percent Bench, Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9275 Second Row, 60 Percent Bench, Cushion (Part 1) Second Row, 60 Percent Bench, Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9276 Second Row, 40 Percent Bench, Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9277 Second Row, 40 Percent Bench, Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9278 Second Row, 40 Percent Bench, Cushion Exploded View Removal and Installation 1. CAUTION: Use care when separating the seat upholstery from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat cushion foam pad. Release the cushion trim cover J-clips, separate the hook-and-loop fasteners and remove one row of hog rings. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9279 2. Release the cable from the seat riser and remove the cushion trim cover. 3. To install, reverse the removal procedure. Seat Backrest Cover - Third Row SEAT BACKREST COVER - THIRD ROW Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9280 Third Row Seat Backrest Third Row Seat Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9281 Third Row Seat Cushion (Part 2) Exploded View Removal and Installation 1. Fold the backrest not being serviced down. 2. Release the backrest trim cover J-clip at the top of the trim cover by the head restraint. - Pull the head restraint release strap through the backrest trim cover. 3. Remove the 2 head restraint-to-backrest frame bolts and remove the head restraint. - To install, tighten to 25 Nm (18 lb-ft). 4. Remove 2 bolts and the hinge cover. 5. Remove 2 bolts and the latch cover. 6. Release the backrest trim cover lower J-clip. 7. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Release the backrest trim cover side J-clips, hook-and-loop strips, invert and remove the backrest trim cover. 8. To install, reverse the removal procedure. Seat Cushion Cover - Third Row SEAT CUSHION COVER - THIRD ROW Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9282 Third Row Seat Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9283 Third Row Seat Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Backrest Cover - Front > Page 9284 Third Row Seat Cushion (Part 2) Exploded View Removal and Installation 1. Remove the third row seat from the vehicle. 2. Release the cushion trim cover retainers attached to the bottom of the cushion frame. 3. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Invert the cushion trim cover, release the hook-and-loop strips and separate the cushion trim cover from the cushion foam pad. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > Customer Interest for Seat Cushion: > 07-25-10 > Dec > 07 > Interior - Outside Seat Cushion Shield is Loose Seat Cushion: Customer Interest Interior - Outside Seat Cushion Shield is Loose TSB 07-25-10 12/24/07 LOOSE OUTSIDE SEAT CUSHION SHIELD- VEHICLES BUILT BEFORE 7/1/2007 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer ISSUE Some 2006-2008 Explorer, Mountaineer and 2007-2008 Sport Trac vehicles built before 7/1/2007 may exhibit a loose outside seat cushion shield. A new bracket was developed to prevent the outside cushion shield from losing retention to the seat base. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Inspect for a retention bracket. (Figure 1) a. If retention bracket is present do not continue with this TSB. b. If no retention bracket is present proceed to Step 2. 2. Position the driver and passenger seats rearward. 3. Install the new retention bracket over the seat base wire support. (Figure 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > Customer Interest for Seat Cushion: > 07-25-10 > Dec > 07 > Interior - Outside Seat Cushion Shield is Loose > Page 9293 4. Align the retention bracket over the cushion side shield spring clip mounting boss hole and attach the cushion side shield. (Figure 2) NOTE DO NOT REPLACE THE OUTSIDE CUSHION SHIELD IF THE FRONT SPRING CLIP IS LOOSE, AS THE NEW BRACKET AND SCREW WILL PROVIDE THE PROPER RETENTION. 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 072510A 2006-2008 Explorer, 0.2 Hr. Mountaineer, 2007-2008 Sport Track: Install Outside Seat Cushion Shield Bracket One Seat 072510B 2006-2008 Explorer, 0.3 Hr. Mountaineer, 2007-2008 Sport Track: Install Outside Seat Cushion Shield Bracket Both Seats DEALER CODING CONDITION BASIC PART NO. CODE 7862900 07 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cushion: > 07-25-10 > Dec > 07 > Interior - Outside Seat Cushion Shield is Loose Seat Cushion: All Technical Service Bulletins Interior - Outside Seat Cushion Shield is Loose TSB 07-25-10 12/24/07 LOOSE OUTSIDE SEAT CUSHION SHIELD- VEHICLES BUILT BEFORE 7/1/2007 FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac MERCURY: 2006-2008 Mountaineer ISSUE Some 2006-2008 Explorer, Mountaineer and 2007-2008 Sport Trac vehicles built before 7/1/2007 may exhibit a loose outside seat cushion shield. A new bracket was developed to prevent the outside cushion shield from losing retention to the seat base. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Inspect for a retention bracket. (Figure 1) a. If retention bracket is present do not continue with this TSB. b. If no retention bracket is present proceed to Step 2. 2. Position the driver and passenger seats rearward. 3. Install the new retention bracket over the seat base wire support. (Figure 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cushion: > 07-25-10 > Dec > 07 > Interior - Outside Seat Cushion Shield is Loose > Page 9299 4. Align the retention bracket over the cushion side shield spring clip mounting boss hole and attach the cushion side shield. (Figure 2) NOTE DO NOT REPLACE THE OUTSIDE CUSHION SHIELD IF THE FRONT SPRING CLIP IS LOOSE, AS THE NEW BRACKET AND SCREW WILL PROVIDE THE PROPER RETENTION. 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 072510A 2006-2008 Explorer, 0.2 Hr. Mountaineer, 2007-2008 Sport Track: Install Outside Seat Cushion Shield Bracket One Seat 072510B 2006-2008 Explorer, 0.3 Hr. Mountaineer, 2007-2008 Sport Track: Install Outside Seat Cushion Shield Bracket Both Seats DEALER CODING CONDITION BASIC PART NO. CODE 7862900 07 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement Seat Cushion: Removal and Replacement SEAT CUSHION - THIRD ROW Third Row Seat Backrest Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 9302 Third Row Seat Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 9303 Third Row Seat Cushion (Part 2) Exploded View Removal and Installation 1. Position the backrest to the upright position. 2. Remove the third row seat from the vehicle. 3. NOTE: The backrest must be up to access the bolts. Remove the latch-to-cushion frame bolt and the hinge-to-cushion frame bolt. To install, tighten to 25 Nm (18 lb-ft). 4. From under the front of the cushion frame, release the cushion trim cover from the studs to access the 2 cushion pivot link assembly-to-cushion frame nuts. 5. Remove the 2 cushion pivot link assembly-to-cushion frame nuts. Remove the cushion assembly. - To install, tighten to 22 Nm (16 lb-ft). 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 9304 Seat Cushion: Overhaul Seat Cushion - Front SEAT CUSHION - FRONT Special Tool(s) Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 9305 Driver Seat Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 9306 Driver Seat Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 9307 Passenger Seat Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 9308 Passenger Seat Cushion (Part 2) Disassembly and Assembly 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. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Never probe the connector on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - 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. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 9309 All seats 1. Remove the front seat and depower the supplemental restraint system (SRS). 2. Remove the seat track. 3. Remove the front seat backrest. 4. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Release the hook-and-loop strips, remove the hog rings and separate the cushion trim cover from the cushion foam pad. Seat with heat 5. If necessary, remove the cushion heated seat mat and route out the wire harness through the cushion foam pad opening. All seats 6. To assemble, reverse the disassembly procedure. 7. Install the front seat backrest. 8. Install the seat track. 9. Install the front seat and repower the SRS. If a passenger seat has been serviced, do not prove out the SRS at this time. Passenger seat 10. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. Seat Cushion - Second Row, 40 Percent E-Z Entry SEAT CUSHION - SECOND ROW, 40 PERCENT E-Z ENTRY Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 9310 Second Row, 40 Percent, E-Z Entry Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 9311 Second Row, 40 Percent, E-Z Entry Cushion (Part 2) Disassembly 1. Remove the second row 40 percent E-Z entry seat from the vehicle. 2. Lower the backrest and position the seat to the E-Z entry position. - The latch feet should be released from the mounting plate and the cushion and backrest must be pivoted up. 3. Using the kneeling mechanism release handle on the backrest, pull the handle and position the kneeling mechanism down in the fold flat load floor position. The cushion and backrest of the seat will be in the E-Z entry position and the kneeling mechanism will be in the fold flat load floor position. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 9312 4. NOTE: The shock should be fully extended when removing. Remove the shock from the seat assembly. Pry the retaining clip out and separate the shock at the mounting plate and cushion frame. 5. Remove the second row 40 percent E-Z entry seat backrest. 6. Remove 3 screws, recliner handle and outboard recliner outer cover. 7. Remove 2 screws and the inboard recliner outer cover. 8. Remove the 2 screws and the latch feet release bar. 9. Release all the cushion trim cover retainers and pin-type retainers. 10. Remove the cushion trim cover and cushion foam pad from the cushion frame. 11. CAUTION: Use care when separating the cushion trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the cushion foam pad. Release the hook-and-loop strips and separate the cushion trim cover from the cushion foam pad. 12. Remove 2 outboard recliner-to-cushion frame bolts and separate the outboard recliner. 13. Remove the outboard recliner inner cover. 14. Remove the outboard recliner. 1. Rotate the cable casing out of the outboard recliner. 2. NOTE: The cable ends are color coded/keyed to the levers. Rotate the cable ends out of the outboard recliner levers. 3. Remove the outboard recliner. 15. Remove the 2 screws, pull to separate and remove the kneeling mechanism inboard leg inner and outer covers. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 9313 16. Separate the cable to the kneeling mechanism inboard leg. 1. Turn and separate the cable casing retainer at the inboard side of the kneeling mechanism inboard leg. 2. Separate the cable from the kneeling mechanism inboard leg release lever. - Remove any cable casing retainers. 17. Remove 2 bolts, the spacer and the latch feet retracting link. 18. Remove the 2 screws and the 2 latch foot covers. 19. Separate the cable and casing from the outboard latch foot. Remove the cable assembly. 20. Remove the screw and separate the kneeling mechanism release cable pivot at the inboard recliner. 21. Remove the 2 screws, pull to separate and remove the kneeling mechanism outboard leg inner and outer covers. 22. Separate the cable to the kneeling mechanism outboard leg and cushion frame. 1. Turn and separate the cable casing retainer at the inboard side of the outboard kneeling mechanism leg. 2. Separate the cable from the outboard kneeling mechanism leg release lever. 3. Separate any cable casing retainers to the cushion frame and remove the cable. 23. Remove the 2 inboard recliner-to-cushion frame bolts, the safety belt buckle and separate the inboard recliner with recliner release shaft. - If necessary, separate the recliner release shaft from the inboard recliner. 24. Remove the inboard recliner inner cover. 25. Remove the cushion frame. - Remove the 2 kneeling mechanism-to-cushion frame bolts. - Remove the 2 latch feet assembly-to-cushion frame bolt. - Remove the cushion frame. 26. Using the release lever, manually release the inboard and outboard latch feet and remove the latch feet assembly. 27. Remove the 2 nuts and remove the kneeling mechanism. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 9314 Assembly 1. Position the kneeling mechanism to the mounting plate and install the nuts. - Tighten to 41 Nm (30 lb-ft). 2. NOTE: Latch feet will hang down lower than the mounting plate, potentially causing the latch feet to partially latch. Make sure the latch feet are completely latched. Position the latching feet assembly to the mounting plate strikers and latch the feet in place. 3. Install the cushion frame. - Position the cushion frame to the latch feet assembly and kneeling mechanism. - Install the 2 latch feet assembly-to-cushion frame bolts. Tighten to 45 Nm (33 lb-ft). - Install the 2 kneeling mechanism-to-cushion frame bolts. Tighten to 45 Nm (33 lb-ft). 4. Position the recliner release shaft onto the inboard recliner release pivot stub. 5. Position the inboard recliner and recliner release shaft to the cushion frame. - Position the inboard recliner to the cushion frame with the recliner release shaft through the cushion frame opening. - Position the safety belt buckle to the inboard recliner forward bolt hole and install the 2 inboard recliner-to-cushion frame bolts. - Tighten to 55 Nm (41 lb-ft). 6. NOTE: The cable ends are color coded/keyed to the levers. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 9315 Position each keyed cable end to the outboard recliner lever and rotate to the locked position. Install the cable casing to the outboard recliner. 7. Position the outboard recliner release pivot stub into the recliner shaft and install the outboard recliner-to-cushion frame bolts. - Tighten to 55 Nm (41 lb-ft). 8. Route the outboard recliner short cable, attach the cable to the latch feet assembly outboard foot and attach the cable casing retainers. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 9316 9. Route the outboard recliner long cable, attach it to the kneeling mechanism inboard leg and attach all cable casing retainers. 10. Route the kneeling mechanism release cable, position the cable pivot at the inboard recliner and install the screw. 11. Install the cable to the kneeling mechanism outboard leg and cushion frame. - Attach the cable to the kneeling mechanism outboard leg release lever. - Position, turn and install the cable casing retainer at the inboard side of the kneeling mechanism outboard leg. - Attach any cable casing retainers. 12. Position the 2 latch foot covers and install the 2 screws. 13. Position the inner and outer covers around the kneeling mechanism outboard leg and install the 2 screws. 14. Position the inner and outer covers around the kneeling mechanism inboard leg and install the 2 screws. 15. Install the latch feet retracting link. - Position the spacer between the latch feet retracting link and inboard latch foot. - Install the bolt through the latch feet retracting link and spacer and into the inboard latch foot. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 9317 - Install the latch feet retracting link bolt into the kneeling mechanism inboard leg. Tighten to 8 Nm (71 lb-in). 16. Position the inboard and outboard recliner inner covers. 17. Align the cushion trim cover to the cushion foam pad and attach the hook-and-loop strips. 18. Position the cushion foam pad and trim cover to the cushion frame and attach the cushion trim cover retainers and pin-type retainers. - Make sure the LATCH is accessible to the occupant. 19. Position the latch feet release bar and install the 2 screws. 20. Install the second row, 40 percent E-Z entry seat backrest. 21. Lower the backrest and position the seat to the E-Z entry position. - The latch feet should be released from the mounting plate and the cushion and backrest must be pivoted up. 22. Using the kneeling mechanism release handle on the backrest, pull the handle and position the kneeling mechanism down in the fold flat load floor position. The cushion and backrest of the seat will be in the E-Z entry position and the kneeling mechanism will be in the fold flat load floor position. 23. NOTE: The shock should be fully extended when installed. Position and install the shock onto the seat assembly. 24. Install the second row, 40 percent E-Z entry seat into the vehicle. 25. Cycle the backrest down and then back to the upright position. Make sure the inboard and outboard recliners simultaneously and securely lock in the upright position. Seat Cushion - Second Row, 60 Percent, E-Z Entry SEAT CUSHION - SECOND ROW, 60 PERCENT, E-Z ENTRY Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 9318 Second Row, 60 Percent, E-Z Entry Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 9319 Second Row, 60 Percent, E-Z Entry Cushion (Part 2) Disassembly 1. Remove the second row, 60 percent E-Z entry seat from the vehicle. 2. Lower the backrest and position the seat to the E-Z entry position. - The latch feet should be released from the mounting plate and the cushion and backrest must be pivoted up. 3. Using the kneeling mechanism release handle on the backrest, pull the handle and position the kneeling mechanism down in the fold flat load floor position. The cushion and backrest of the seat will be in the E-Z entry position and the kneeling mechanism will be in the fold flat load floor position. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 9320 4. NOTE: The shock should be fully extended when removing. Remove the shock from the seat assembly. Pry the retaining clip out and separate the shock from the seat assembly at each end. 5. Remove the second row 60 percent E-Z entry seat backrest. 6. Remove 3 screws, recliner handle and outboard recliner outer cover. 7. Remove the 2 screws and the latch feet release bar. 8. Release all the cushion trim cover retainers and pin-type retainers. 9. Remove the cushion trim cover and cushion foam pad from the cushion frame. 10. CAUTION: Use care when separating the cushion trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the cushion foam pad. Release the hook-and-loop strips and separate the cushion trim cover from the cushion foam pad. 11. Remove 2 outboard recliner-to-cushion frame bolts, pull out and separate the outboard recliner. 12. Remove the outboard recliner inner cover. 13. Remove the outboard recliner. 1. Rotate the cable casing out of the outboard recliner. 2. NOTE: The cable ends are color coded/keyed to the levers. Rotate the cable ends out of the outboard recliner levers. 3. Remove the outboard recliner. 14. Remove the 2 screws, pull to separate and remove the kneeling mechanism inboard leg inner and outer covers. 15. Remove the 2 screws, pull to separate and remove the kneeling mechanism outboard leg inner and outer covers. 16. Remove the bolt and spacer and separate the latch feet retracting link from the latch feet assembly. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 9321 17. Release the tab and slide the latch feet retracting link retainer back. 18. Release the tab and remove the latch feet retracting link from the kneeling mechanism. 19. NOTE: Note the routing of the cable for installation. Separate the cable to the kneeling mechanism inboard leg and cushion frame. 1. Turn and separate the cable casing retainer at the inboard side of the kneeling mechanism inboard leg. 2. Separate the cable from the kneeling mechanism inboard leg release lever. - Remove the cable casing retainers from the cushion frame. 20. Remove the 2 screws and the 2 latch foot covers. 21. Separate the cable and casing from the outboard latch foot, cushion support springs and remove the cable assembly. 22. Through the opening in the cushion frame, remove the recliner release shaft. 23. NOTE: Note the routing of the cable for installation. Separate the kneeling mechanism cable pivot at the inboard recliner. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 9322 24. NOTE: Note the routing of the cable for installation. Remove the kneeling mechanism release handle with cable. 1. Turn and separate the cable casing retainer at the inboard side of the outboard kneeling mechanism leg. 2. Separate the cable from the outboard kneeling mechanism leg release lever. 3. Separate any cable casing retainers to the cushion frame and remove the kneeling mechanism release handle with cable. 25. Remove the cushion frame. - Remove the cushion frame-to-kneeling mechanism bolt. - Remove the cushion frame-to-latch foot assembly bolt. - Remove the 2 inboard recliner-to-cushion frame bolts. - Remove the cushion frame. 26. Remove the 2 bolts and the safety belt buckles. 27. Remove the inboard recliner. - Remove the inboard recliner-to-kneeling mechanism bolt. - Remove the inboard recliner-to-latch feet assembly bolt. - Remove the inboard recliner. Remove the inboard recliner inner cover. 28. Using the release levers, manually release the inboard and outboard latch feet and remove the latch feet assembly from the mounting plate. 29. Remove the 2 kneeling mechanism-to-mounting plate nuts and remove the kneeling mechanism. Assembly 1. Position the kneeling mechanism to the mounting plate and install the 2 kneeling mechanism-to-mounting plate nuts. - Tighten to 41 Nm (30 lb-ft). 2. NOTE: Latch feet will hang down lower than the mounting plate, potentially causing the latch feet to partially latch. Make sure the latch feet are completely latched. Position the latch feet assembly to the mounting plate strikers and latch the feet in place. 3. Install the inboard recliner inner cover. 4. Position the inboard recliner. - Position the inboard recliner to the kneeling mechanism and latch feet assembly. - Hand start the latch feet assembly-to-inboard recliner bolt. - Hand start the kneeling mechanism-to-inboard recliner bolt. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 9323 5. Position the recliner release shaft onto the inboard recliner release pivot stub. 6. Position the cushion frame to the inboard recliner with the recliner release shaft through the cushion frame opening. 7. Hand start the 2 inboard recliner-to-cushion frame bolts. 8. Hand start the cushion frame-to-latch foot assembly bolt and the cushion frame-to-kneeling mechanism bolt. 9. Install the bolts. - Install the inboard recliner-to-latch feet assembly bolt. Tighten to 55 Nm (41 lb-ft). - Install the inboard recliner-to-kneeling mechanism bolt. Tighten to 55 Nm (41 lb-ft). - Install the cushion frame-to-latch foot assembly bolt. Tighten to 55 Nm (41 lb-ft). - Install the cushion frame-to-kneeling mechanism bolt. Tighten to 55 Nm (41 lb-ft). - Install the inboard recliner-to-cushion frame rear bolt. Tighten to 40 Nm (30 lb-ft). - Install the inboard recliner-to-cushion frame front bolt. Tighten to 40 Nm (30 lb-ft). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 9324 10. NOTE: The cable ends are color coded/keyed to the levers. Position each keyed cable end to the outboard recliner lever and rotate to the locked position. Install the cable casing to the outboard recliner. 11. Install the outboard recliner inner cover. 12. NOTE: The outboard recliner inner cover has been removed for clarity. Position the outboard recliner release pivot stub into the recliner shaft and install the 2 outboard recliner-to-cushion frame bolts. Tighten to 55 Nm (41 lb-ft). 13. Install the outboard recliner short cable to the latch feet assembly outboard foot and attach all cable casing retainers. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 9325 14. Install the outboard recliner long cable to the kneeling mechanism inboard leg and attach all cable casing retainers. 15. Route the kneeling mechanism release cable, position the kneeling mechanism release cable pivot at the inboard recliner and attach all cable casing retainers. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 9326 16. Make sure the inboard recliner pin is through the cable pivot. 17. Install the kneeling mechanism release cable to the kneeling mechanism outboard leg. - Attach the cable to the kneeling mechanism outboard leg release lever. - Position, turn and install the cable casing retainer at the inboard side of the kneeling mechanism outboard leg. - Attach any cable casing retainers. 18. Position the inner and outer covers around the kneeling mechanism outboard leg and install the 2 screws. 19. Position the inner and outer covers around the kneeling mechanism inboard leg and install the 2 screws. 20. Position the 2 latch foot covers and install the 2 screws. 21. Position the latch feet retracting link retainer onto the latch feet retracting link shaft. 22. Position the latch feet retracting link into the kneeling mechanism coupler engaging the retainer. - The kneeling mechanism coupler is part of the kneeling mechanism. 23. Slide the latch feet retracting link retainer back to the kneeling mechanism coupler, engaging the retainer. 24. Position the spacer between the latch feet retracting link and outboard latch foot and install the bolt. 25. Align the safety belt buckle anti-rotation tabs to the cushion frame openings and install the 2 bolts. - Tighten to 40 Nm (30 lb-ft). 26. Align the cushion trim cover to the cushion foam pad and attach the hook-and-loop strips. 27. Position the cushion foam pad and trim cover to the cushion frame and attach the cushion trim cover retainers and pin-type retainers. - Pull the 2 safety belt buckles through the cushion trim cover and foam pad. - Make sure the LATCH is accessible to the occupant. 28. Position the latch feet release bar and install the 2 screws. 29. Install the second row, 60 percent E-Z entry seat backrest. 30. Lower the backrest and position the seat to the E-Z entry position. - The latch feet should be released from the mounting plate and the cushion and backrest must be pivoted up. 31. Using the kneeling mechanism release handle on the backrest, pull the handle and position the kneeling mechanism down in the fold flat load floor position. The cushion and backrest of the seat will be in the E-Z entry position and the kneeling mechanism will be in the fold flat load floor position. 32. NOTE: The shock should be fully extended when installed. Position and install the shock onto the seat assembly. 33. Install the second row, 60 percent E-Z entry seat into the vehicle. 34. Cycle the backrest down and then back to the upright position. Make sure the inboard and outboard recliners simultaneously and securely lock in the upright position. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 9327 Seat Cushion - Second Row, 40 Percent, Bench SEAT CUSHION - SECOND ROW, 40 PERCENT, BENCH Disassembly and Assembly 1. Remove the second row, 40 percent of 60/40 bench seat. 2. Remove the second row, 40 percent of 60/40 bench seat backrest. 3. CAUTION: Use care when separating the seat upholstery from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat cushion foam pad. Release the J-clips, separate the hook-and-loop fasteners and remove the seat cushion trim cover. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 9328 4. Remove the cushion foam pad. 5. Remove the cushion pad supports. 6. To assemble, reverse the disassembly procedure. Seat Cushion - Second Row, 60 Percent, Bench SEAT CUSHION - SECOND ROW, 60 PERCENT, BENCH Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 9329 Part 2 Disassembly and Assembly 1. Remove the second row, 60 percent bench seat. 2. Remove the second row, 60 percent bench seat backrest. 3. CAUTION: Use care when separating the cushion trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the cushion foam pad. Release the J-clips, separate the hook-and-loop fasteners, remove the hog rings and the cushion trim cover. 4. Remove the cushion foam pad. 5. Remove 2 cushion pad supports. 6. Remove the screw and the release handle. 7. Remove the 3 screws and the latch cover. 8. Remove the 2 lower outboard latch bolts. - To install, tighten to 40 Nm (30 lb-ft). 9. Remove the remaining lower inboard latch bolt. - To install, tighten to 75 Nm (55 lb-ft). 10. CAUTION: Do not detach the latch cable from the seat latches. The latch assembly is synchronized; if disassembled, the latch assembly may not operate correctly. Remove the latch assembly. Do not separate or disassemble the latch assembly components. 11. To assemble, reverse the disassembly procedure. Seat Cushion - Second Row, Bucket SEAT CUSHION - SECOND ROW, BUCKET Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 9330 Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 9331 Part 2 Disassembly and Assembly NOTE: LH seat shown, RH similar. 1. Remove the second row bucket seat. 2. Remove the second row bucket seat backrest. 3. Remove the screw and the release handle. 4. Remove the 2 screws and the 2 LH latch covers. 5. Remove the 2 screws and the 2 RH latch covers. 6. CAUTION: Use care when separating the seat upholstery from the hook-and-loop strip, or the hook-and-loop strip can be torn from the seat cushion foam pad. Release the cushion trim cover J-clips, separate the hook-and-loop fasteners and remove one row of hog rings. 7. Release the cable from the seat riser and remove the cushion trim cover. 8. Remove the seat cushion foam pad. 9. Remove the 2 lower latch cover screws and the 2 LH lower latch covers. 10. NOTE: The left and right latches with cables are one assembly and should not be separated. Remove the 4 latch bolts and the latch pivot. To install, tighten to 40 Nm (30 lb-ft). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 9332 11. Remove the 2 latch nuts and separate the latch assembly. - To install, tighten to 40 Nm (30 lb-ft). 12. NOTE: On assembly, route the cable as shown. Remove the riser attachment cable and the latch assembly. 13. Remove the torsion rod and the cushion pad support. 14. Remove the front spring hinge bolts, springs and seat cushion frame assembly. - To install, tighten to 23 Nm (17 lb-ft). 15. To assemble, reverse the disassembly procedure. Seat Cushion - Third Row Third Row Seat Cushion SEAT CUSHION - THIRD ROW Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 9333 Third Row Seat Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 9334 Third Row Seat Cushion (Part 2) Disassembly and Assembly 1. Remove the third row seat from the vehicle. 2. Remove the third row cushion. 3. Release the cushion trim cover J-clips attached to the bottom of the cushion frame. 4. Remove the cushion foam pad and trim cover from the cushion frame. 5. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Invert the cushion trim cover, release the hook-and-loop strips and separate the cushion trim cover from the cushion foam pad. 6. To assemble, reverse the disassembly procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions Seat Heater: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9339 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9340 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9341 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9342 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9343 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9344 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9345 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9346 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9347 Seat Heater: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9348 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9349 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9350 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9351 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9352 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9353 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9354 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9355 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9356 Seat Heater: Connector Views C334 C364 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9357 C335 C365 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9358 Seat Heater: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 119-1 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams By Number. See: Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 9359 Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. See: Diagrams/Components/Component Location Views Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Page 9363 C2347 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch Seat Heater Switch: Service and Repair Heated Seat Switch HEATED SEAT SWITCH Removal and Installation 1. Position the gear selector to NEUTRAL. 2. Remove the console trim ring. 3. Open the center console door, remove the 2 screws and pull up on the console finish panel to release the retainers. 4. Disconnect the power point electrical connector and remove the console finish panel. 5. Pull out to release the retainers and separate the instrument panel center lower RH and LH finish panels. 6. Pull out to release the retainers and separate the instrument panel center finish panel. 7. Disconnect the electrical connector, release the 4 tabs and remove the heated seat/heated windshield switch pack. 8. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 9366 Seat Heater Switch: Service and Repair Seat Control Switch SEAT CONTROL SWITCH Special Tool(s) Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 9367 Front Seat Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 9368 Front Seat Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 9369 Driver Seat Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 9370 Driver Seat Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 9371 Passenger Seat Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 9372 Passenger Seat Cushion (Part 2) Exploded View Removal and Installation WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an airbag module. This will reduce the risk of injury in the event of an accidental deployment. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - 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. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All seats 1. Remove the front seat and depower the supplemental restraint system (SRS). 2. Remove the cushion side shield. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 9373 1. If equipped, remove the clip and manual recline handle. 2. If equipped, pull and remove the manual lumbar control knob. 3. Remove the scrivet. 4. Release the cushion side shield front clip. 5. From under the cushion side shield, release the 3 hook retainers. 6. Pull out on the cushion side shield at the back and release the pin-type retainer. 7. Separate the cushion trim cover elastic strap from the cushion side shield. 8. Remove the seat control switch knob and separate the seat control switch from the cushion side shield. - Remove the cushion side shield. 3. Disconnect and remove the seat control switch. 4. To install, reverse the removal procedure. 5. Install the front seat and repower the SRS. If a passenger seat has been serviced, do not prove out the SRS at this time. Passenger seat 6. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 9374 Seat Heater Switch: Service and Repair Seat Control Switch - Third Row SEAT CONTROL SWITCH - THIRD ROW Removal and Installation 1. Pull out on the third row seat control switch bezel and separate from the LH quarter trim panel. 2. Disconnect the third row seat control switch(es), release the retainers and remove the third row seat control switch(es). 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair Seat Latch: Service and Repair SEAT LATCH - THIRD ROW, MANUAL Removal and Installation LH or RH latch 1. Position both of the third row seat backrests up. 2. Remove the RH latch-to-cushion frame bolt. - To install, tighten to 25 Nm (18 lb-ft). LH latch 3. Remove the LH latch-to-cushion frame bolt. - To install, tighten to 25 Nm (18 lb-ft). LH or RH latch 4. Position the third row seat LH backrest down. 5. Remove the vehicle jack. 6. Remove the 2 bolts and the vehicle jack mounting bracket. 7. Remove the 2 screws and the RH latch cover. 8. Separate the cable and casing from the RH latch. 9. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Release the RH seat backrest trim cover lower and inboard J-clips and roll the backrest trim cover up to access the 2 RH latch-to-backrest frame bolts. 10. Remove the 2 RH latch-to-backrest frame bolts. - To install, tighten to 25 Nm (18 lb-ft). 11. Remove the floor mounting bracket center front and rear nuts. - To install, tighten to 40 Nm (30 lb-ft). 12. Remove the 2 latch-to-floor mounting bracket nuts. - To install, tighten to 22 Nm (16 lb-ft). 13. Remove the RH latch. LH latch 14. Position the third row seat LH backrest up and the RH backrest down. 15. Remove the 2 screws and the LH latch cover. 16. Separate the cable and casing from the LH latch. 17. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or the hook-and-loop strip can be torn from the backrest foam pad. Release the LH seat backrest trim cover lower and inboard J-clips and roll the backrest trim cover up to access the 2 LH latch-to-backrest frame bolts. 18. Remove the 2 LH latch-to-backrest frame bolts. - To install, tighten to 25 Nm (18 lb-ft). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Page 9378 19. Remove the LH latch. 20. Remove the safety belt buckle assembly-to-latch nut and remove the safety belt buckle assembly. - To install, tighten to 75 Nm (55 lb-ft). Both latches 21. To install, reverse the removal procedure. - The latch(es) must be in the backrest fold down position to install. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair Seat Track: Service and Repair SEAT TRACK Special Tool(s) Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page 9382 Front Seat Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page 9383 Front Seat Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page 9384 Driver Seat Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page 9385 Driver Seat Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page 9386 Passenger Seat Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page 9387 Passenger Seat Cushion (Part 2) Exploded View Removal and Installation WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an airbag module. This will reduce the risk of injury in the event of an accidental deployment. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - 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. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All seats 1. Remove the front seat and depower the supplemental restraint system (SRS). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page 9388 Passenger seat with failed horizontal motor 2. To remove the occupant classification sensor (OCS) rails, remove the 2 horizontal screw block bolts. This will allow the power seat tracks to move independently of each other for access to the 8 OCS rail bolts. Passenger seat receiving a new seat track 3. Remove the inboard and outboard OCS rails. Passenger seat not receiving a new seat track 4. NOTE: Note the position and the routing of the OCS sensor wiring, connector and wiring retainers for installation. Detach the 2 OCS wiring retainers at each OCS rail. Then using a suitable tool, release the tab and disconnect the RH and LH OCS rail electrical connectors. All seats 5. Remove the cushion side shield. 1. If equipped, remove the clip and manual recline handle. 2. If equipped, pull and remove the manual lumbar control knob. 3. Remove the scrivet. 4. Release the cushion side shield front clip. 5. From under the cushion side shield, release the 3 hook retainers. 6. Pull out on the cushion side shield at the back and release the pin-type retainer. 7. Separate the cushion trim cover elastic strap from the cushion side shield. - If equipped with a manual seat track, remove the cushion side shield. 8 If equipped with power seats, remove the seat control switch knob and separate the seat control switch from the cushion side shield. Remove the cushion side shield. Power seat 6. Separate the seat control switch wire harness pin-type retainer from the cushion frame. Driver seat Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page 9389 7. Disconnect the SRS seat position sensor. 8. Driver seat with 10-way power, disconnect the backrest power feed electrical connector and route out the wire harness. - Release any wire harness retainers. Heated seat 9. NOTE: Passenger seat shown, driver seat similar. Disconnect the cushion and backrest heated seat mat electrical connectors. All seats 10. Release the pin-type retainers, disconnect and route out the side air bag module electrical connector and wire harness. 11. Remove the safety belt buckle and pretensioner electrical connector cover. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page 9390 12. Disconnect the safety belt buckle and pretensioner electrical connector and safety belt buckle switch electrical connector. 13. Release all the cushion trim cover retainers. 14. Remove the seat cushion foam pad and cushion trim cover. 15. Remove the 4 cushion frame-to-seat track nuts and the seat track. - To install, tighten to 36 Nm (27 lb-ft). Driver seat with failed horizontal motor 16. If necessary, remove the inboard horizontal screw block bolt. This will allow the inboard power seat track to move independently so the safety belt buckle and pretensioner can be removed. All seats 17. To install, reverse the removal procedure. 18. Install the front seat and repower the SRS. If a passenger seat has been serviced, do not prove out the SRS at this time. Passenger seat 19. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Vacuum/Pressure Pump, Seats > Component Information > Locations View 151-19 (Driver Seat) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Seats > Vacuum/Pressure Pump, Seats > Component Information > Locations > Page 9394 C366 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Console Lamp Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door Console Lamp Switch: Service and Repair Door Ajar Switch - Front Door DOOR AJAR SWITCH - FRONT DOOR Removal and Installation 1. Remove the front door latch. 2. Disconnect the front door ajar switch electrical connector. 3. Release the locking tab and rotate the front door ajar switch counterclockwise and remove the switch from the front door latch. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Console Lamp Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 9400 Console Lamp Switch: Service and Repair Door Ajar Switch - Rear Door DOOR AJAR SWITCH - REAR DOOR Removal and Installation 1. Remove the rear door latch. 2. Release the locking tab, rotate the rear door ajar switch counterclockwise and remove the switch from the rear door latch. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Console Lamp Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 9401 Console Lamp Switch: Service and Repair Door Ajar Switch - Liftgate DOOR AJAR SWITCH - LIFTGATE Removal and Installation 1. Remove the liftgate latch. 2. Release the locking tab, rotate the liftgate ajar switch counterclockwise and remove the ajar switch form the liftgate latch. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Console Lamp Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 9402 Console Lamp Switch: Service and Repair Door Ajar Switch - Liftgate Glass DOOR AJAR SWITCH - LIFTGATE GLASS Removal and Installation 1. Remove the liftgate window latch. 2. Rotate the liftgate window ajar switch counterclockwise and remove the ajar switch from the liftgate window latch. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 9406 C2089 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side View 151-22 (Passenger Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side > Page 9411 View 151-21 (Driver Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side C505 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side > Page 9414 C605 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 9415 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 9416 Power Door Lock Switch: Service and Repair DOOR LOCK CONTROL SWITCH Removal and Installation NOTE: The LH side is shown, the RH side is similar. 1. Remove the interior door handle cover. 2. Remove the front door switch bezel. - Release the 4 retaining tabs. 3. Disconnect the door lock control switch and window control switch electrical connectors. 4. Remove the door lock control switch. - Release the 4 retaining tabs. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 9417 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations View 151-21 (Driver Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 9421 C527 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 9422 Power Mirror Switch: Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 9423 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 9424 Power Mirror Switch: Service and Repair EXTERIOR MIRROR CONTROL SWITCH Removal and Installation 1. Remove the front door trim panel. 2. Remove the exterior mirror control switch from the front door trim panel. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left/Right View 151-16 (Left Rear, (2 0f 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left/Right > Page 9429 View 151-19 (Driver Seat) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left/Right > Page 9430 View 151-20 (Passenger Seat) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left Power Seat Switch: Diagrams Power Seat Switch, Left C352 C3016 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left > Page 9433 C355 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left > Page 9434 C4179 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left > Page 9435 C4180 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left > Page 9438 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left > Page 9439 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Page 9440 Power Seat Switch: Service and Repair MEMORY SET SWITCH Removal and Installation 1. Position the gear selector to NEUTRAL. 2. Remove the console trim ring. 3. Open the center console door, remove the 2 screws and pull up on the console finish panel to release the retainers. 4. Disconnect the power point electrical connector and remove the console finish panel. 5. Pull out to release the retainers and separate the instrument panel center lower RH and LH finish panels. 6. Pull out to release the retainers and separate the instrument panel center finish panel. 7. Disconnect the electrical connector, release the 4 tabs and remove the memory SET switch. 8. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations View 151-25 (Liftgate) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Page 9444 C4039 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Belt Tower Position Sensor > Component Information > Description and Operation Seat Belt Tower Position Sensor: Description and Operation SEAT TRACK POSITION SENSOR The seat track position sensor is a Hall-effect sensor located on the driver seat track. The seat track position sensor informs the RCM of the driver seat position. Based on programmed limits, the seat track position sensor will inform the RCM of the driver seat position. The RCM uses this information in determining the deployment rate of the dual-stage driver air bag module. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 9451 C2347 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch Seat Heater Switch: Service and Repair Heated Seat Switch HEATED SEAT SWITCH Removal and Installation 1. Position the gear selector to NEUTRAL. 2. Remove the console trim ring. 3. Open the center console door, remove the 2 screws and pull up on the console finish panel to release the retainers. 4. Disconnect the power point electrical connector and remove the console finish panel. 5. Pull out to release the retainers and separate the instrument panel center lower RH and LH finish panels. 6. Pull out to release the retainers and separate the instrument panel center finish panel. 7. Disconnect the electrical connector, release the 4 tabs and remove the heated seat/heated windshield switch pack. 8. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 9454 Seat Heater Switch: Service and Repair Seat Control Switch SEAT CONTROL SWITCH Special Tool(s) Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 9455 Front Seat Backrest (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 9456 Front Seat Backrest (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 9457 Driver Seat Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 9458 Driver Seat Cushion (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 9459 Passenger Seat Cushion (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 9460 Passenger Seat Cushion (Part 2) Exploded View Removal and Installation WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an airbag module. This will reduce the risk of injury in the event of an accidental deployment. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - 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. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All seats 1. Remove the front seat and depower the supplemental restraint system (SRS). 2. Remove the cushion side shield. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 9461 1. If equipped, remove the clip and manual recline handle. 2. If equipped, pull and remove the manual lumbar control knob. 3. Remove the scrivet. 4. Release the cushion side shield front clip. 5. From under the cushion side shield, release the 3 hook retainers. 6. Pull out on the cushion side shield at the back and release the pin-type retainer. 7. Separate the cushion trim cover elastic strap from the cushion side shield. 8. Remove the seat control switch knob and separate the seat control switch from the cushion side shield. - Remove the cushion side shield. 3. Disconnect and remove the seat control switch. 4. To install, reverse the removal procedure. 5. Install the front seat and repower the SRS. If a passenger seat has been serviced, do not prove out the SRS at this time. Passenger seat 6. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 9462 Seat Heater Switch: Service and Repair Seat Control Switch - Third Row SEAT CONTROL SWITCH - THIRD ROW Removal and Installation 1. Pull out on the third row seat control switch bezel and separate from the LH quarter trim panel. 2. Disconnect the third row seat control switch(es), release the retainers and remove the third row seat control switch(es). 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 9466 C2094 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Limit Switch > Component Information > Service and Repair Sunroof / Moonroof Limit Switch: Service and Repair ROOF OPENING PANEL CONTROL SWITCH Removal and Installation 1. Remove the overhead console. 2. Disconnect the overhead console electrical connectors. 3. Disengage the clips and remove the switch from the overhead console. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations View 151-26 (Roof) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 9473 Sunroof / Moonroof Switch: Diagrams C912 C9001 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and Operation > Explorer / Mountaineer Sound Proofing / Insulation: Description and Operation Explorer / Mountaineer INSULATION Insulation is installed: - under the hood. - above and below the instrument panel. - at the cowl side panels. - over the front and rear tunnel. - over the front and rear floor pans. - inside the B-, C- and D-pillars. It has heat-bondable mastic deadeners for improved NVH characteristics. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and Operation > Explorer / Mountaineer > Page 9478 Sound Proofing / Insulation: Description and Operation Sound Deadeners and Insulators Sound Deadeners and Insulators WARNING: Always refer to Material Safety Data Sheet (MSDS) when handling chemicals and wear protective equipment as directed. Examples may include but are not limited to respirators and chemically resistant gloves. Failure to follow these instructions may result in serious personal injury. NOTICE: - Mastic is made of a combustible material and should be removed prior to carrying out welding procedures to the area. Heat zones from welding near the mastic may cause the mastic material to burn. - Corrosion protection must be restored to the area AFTER the mastic material is applied. Corrosion protection products may be wax based and loss of adhesion may occur. NOTE: - The following illustrations serve as a reference to indicate mastic patch (butyl pad) locations. Additional insulators and sound deadeners are used beyond those indicated in the illustration. - To restore the vehicle to design intent, missing or damaged sound deadeners and insulators should be installed new with the correct service replacement component. Sound Deadeners and Insulators - Explorer Sport Trac Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and Operation > Explorer / Mountaineer > Page 9479 Sound Deadeners and Insulators - Explorer/Mountaineer 1. NOTE: In applications where mastic material is applied as a pumpable material at the factory, replacement of missing or damaged mastic is acceptable in the form of cut-to-fit butyl pad(s) or pumpable mastic material(s) when carrying out repairs. Whenever replacement of an existing mastic insulator is carried out, the surface must be thoroughly cleaned to make sure correct adhesion will occur. The surface should be 10°C (50°F) or greater before applying the mastic. The use of a heat gun to warm the metal surface will aid in adhesion. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair Tailgate Latch: Service and Repair TAILGATE LATCH Removal and Installation 1. Open and support the tailgate. 2. Remove the 7 bolts, the 4 pin-type retainers and the tailgate access panel. - To install, tighten to 5 Nm (44 lb-in). 3. Open the clip and release the tailgate latch actuating rod from the tailgate remote control. 4. Release the tailgate latch actuating rod locator from the tailgate. 5. Remove the 2 bolts and the tailgate latch. - To install, tighten to 25 Nm (18 lb-ft). 6. Remove the tailgate latch actuating rod. 7. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair Tailgate Release Handle: Service and Repair TAILGATE RELEASE HANDLE Removal and Installation 1. Remove the tailgate latch remote control. 2. Remove the tailgate release handle. 3. To install, reverse the removal procedure. - Lubricate the tailgate release handle after installation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 1. Remove the wiper pivot arms. CAUTION: To avoid breaking the retaining clips on the cowl panel, do not pull up on the rear of the cowl panel. 2. Pry up on the front of the cowl panel to release it from the retaining clips. 3. Remove the cowl panel grille. 4. Separate the left cowl panel from the right cowl panel by releasing the retaining clips. 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair Front Door Window Glass Weatherstrip: Service and Repair DOOR GLASS TOP RUN - FRONT Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Page 9496 Part 2 Exploded Views Removal and Installation 1. Remove the front door window glass. 2. Remove the exterior moulding. 3. Remove the front door glass top run channel assembly bolt. - To install, tighten to 12 Nm (9 lb-ft). 4. Remove the front door glass top run channel assembly through the top opening of the front door. 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair Rear Door Window Glass Weatherstrip: Service and Repair DOOR GLASS TOP RUN - REAR Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Page 9500 Part 2 Exploded View Removal and Installation 1. Remove the rear door window glass. 2. Remove the exterior moulding. 3. Remove the rear door glass top run assembly bolt. - To install, tighten to 12 Nm (9 lb-ft). 4. Remove the rear door glass top run channel assembly. - Remove the rear door glass top run channel assembly through the top opening of the rear door. 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch View 151-2 (Engine Compartment - 4.0L, (2 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch > Page 9506 View 151-1 (Engine Compartment - 4.0L, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch C277 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch > Page 9509 C278 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Brake Pedal Position (BPP) Switch Brake Switch (Cruise Control): Description and Operation Brake Pedal Position (BPP) Switch BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Brake Pedal Position (BPP) Switch > Page 9512 Brake Switch (Cruise Control): Description and Operation Brake Pedal Switch (BPS) Brake Deactivator Switch BRAKE PEDAL SWITCH (BPS) BRAKE DEACTIVATOR SWITCH The BPS, also called the brake deactivator switch, is for vehicle speed control deactivation. A normally closed switch supplies battery positive voltage (B+) to the PCM when the brake pedal is not applied. When the brake pedal is applied, the normally closed switch opens and power is removed from the PCM. On some applications the normally closed BPS, along with the normally open BPP switch, are used for a brake rationality test within the PCM. The PCM misfire monitor profile learn function may be disabled if a brake switch concern occurs. If one or both brake pedal inputs to the PCM is not changing states when they were expected to, a diagnostic trouble code (DTC) is set by the PCM strategy. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Page 9513 Brake Switch (Cruise Control): Service and Repair SPEED CONTROL DEACTIVATOR SWITCH Removal CAUTION: Do not remove or repair the brake pedal, brake booster or master cylinder without first removing the speed control deactivator switch. Do not install the speed control deactivator switch without the brake pedal arm secured to the brake booster push rod. Do not pull or push on the brake pedal when removing or installing the speed control deactivator switch, as misadjustment or damage to the switch may occur. 1. Disconnect the speed control deactivator switch electrical connector. 2. Rotate counterclockwise 45 degrees and remove the speed control deactivator switch. Installation NOTE: When installing the speed control deactivator switch it is automatically self-adjusting to the proper position. Do not pull up or push down on the pedal during installation. Initial installation of the speed control deactivator switch allows for one adjustment. If additional adjustments are necessary, install a new switch. 1. Install the speed control deactivator switch, and rotate clockwise 45 degrees. 2. Connect the speed control deactivator switch electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Description and Operation Clutch Switch: Description and Operation CLUTCH PEDAL POSITION (CPP) SWITCH Typical Clutch Pedal Position (CPP) Switch The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine load. The PCM uses the load information for mass air flow and fuel calculations. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair Cruise Control Switch: Service and Repair SPEED CONTROL SWITCH Removal and Installation NOTE: - It is not necessary to remove the driver air bag module during this procedure. - Be careful not to allow the speed control switch electrical connector to fall back into the steering wheel. 1. Remove the speed control switch by pulling the switch toward the rear of the vehicle. - Disconnect the electrical connector. 2. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch View 151-2 (Engine Compartment - 4.0L, (2 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Deactivator Switch > Page 9525 View 151-1 (Engine Compartment - 4.0L, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch C277 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Deactivator Switch > Page 9528 C278 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Brake Pedal Position (BPP) Switch Brake Switch (Cruise Control): Description and Operation Brake Pedal Position (BPP) Switch BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Brake Pedal Position (BPP) Switch > Page 9531 Brake Switch (Cruise Control): Description and Operation Brake Pedal Switch (BPS) Brake Deactivator Switch BRAKE PEDAL SWITCH (BPS) BRAKE DEACTIVATOR SWITCH The BPS, also called the brake deactivator switch, is for vehicle speed control deactivation. A normally closed switch supplies battery positive voltage (B+) to the PCM when the brake pedal is not applied. When the brake pedal is applied, the normally closed switch opens and power is removed from the PCM. On some applications the normally closed BPS, along with the normally open BPP switch, are used for a brake rationality test within the PCM. The PCM misfire monitor profile learn function may be disabled if a brake switch concern occurs. If one or both brake pedal inputs to the PCM is not changing states when they were expected to, a diagnostic trouble code (DTC) is set by the PCM strategy. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Page 9532 Brake Switch (Cruise Control): Service and Repair SPEED CONTROL DEACTIVATOR SWITCH Removal CAUTION: Do not remove or repair the brake pedal, brake booster or master cylinder without first removing the speed control deactivator switch. Do not install the speed control deactivator switch without the brake pedal arm secured to the brake booster push rod. Do not pull or push on the brake pedal when removing or installing the speed control deactivator switch, as misadjustment or damage to the switch may occur. 1. Disconnect the speed control deactivator switch electrical connector. 2. Rotate counterclockwise 45 degrees and remove the speed control deactivator switch. Installation NOTE: When installing the speed control deactivator switch it is automatically self-adjusting to the proper position. Do not pull up or push down on the pedal during installation. Initial installation of the speed control deactivator switch allows for one adjustment. If additional adjustments are necessary, install a new switch. 1. Install the speed control deactivator switch, and rotate clockwise 45 degrees. 2. Connect the speed control deactivator switch electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Description and Operation Clutch Switch: Description and Operation CLUTCH PEDAL POSITION (CPP) SWITCH Typical Clutch Pedal Position (CPP) Switch The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine load. The PCM uses the load information for mass air flow and fuel calculations. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair Cruise Control Switch: Service and Repair SPEED CONTROL SWITCH Removal and Installation NOTE: - It is not necessary to remove the driver air bag module during this procedure. - Be careful not to allow the speed control switch electrical connector to fall back into the steering wheel. 1. Remove the speed control switch by pulling the switch toward the rear of the vehicle. - Disconnect the electrical connector. 2. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Air Bag Deactivation Indicator > Component Information > Diagrams C2286 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Air Bag Deactivation Indicator > Component Information > Diagrams > Page 9543 Air Bag Deactivation Indicator: Description and Operation PASSENGER AIR BAG DEACTIVATION (PAD) INDICATOR The passenger air bag deactivation (PAD) indicator is a visual indicator used to inform the front seat occupants of the passenger air bag deactivation state. The PAD indicator is a stand-alone lamp installed into the vehicle instrument panel in a position visible to each front seat occupant. The RCM controls the state of the PAD indicator through a direct hardware connection, based on information provided by the occupant classification sensor (OCS) system. The PAD indicator is lit to indicate the passenger air bag module is disabled. An exemption to this is when the front passenger seat is determined to be empty and passenger safety belt buckle unbuckled, and therefore indication of a deactivated passenger air bag module is not necessary. In all other cases, the PAD indicator is unlit when the passenger air bag module is enabled. When the ignition switch is in the ON position, the PAD indicator prove-out period is initiated by the RCM. The RCM briefly activates the PAD indicator to prove-out the indicator function and verify to the front occupants correct functional operation of the PAD indicator. The PAD indicator will be lit/unlit within 1.0 to 1.5 seconds of a change of state from the OCS system. When an OCS system fault is present, the RCM defaults the passenger air bag module to the last valid state received from the OCS system until the ignition switch is turned OFF. If the OCS system fault is still present when the ignition switch is turned ON, the RCM defaults the passenger air bag module to enabled regardless of the size of occupant in the front passenger seat. The PAD indicator will be unlit. Passenger Air Bag And PAD Indicator Status The above table indicates the passenger air bag status and the PAD indicator status based the size of the front outboard passenger occupant Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Air Bag Deactivation Indicator > Component Information > Diagrams > Page 9544 Air Bag Deactivation Indicator: Service and Repair PASSENGER AIR BAG DEACTIVATION (PAD) INDICATOR Removal and 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. Depower the system. 2. Remove the floor console. 3. Gently pull outward to release the clips on the instrument panel center finish panel. 4. Disconnect the passenger air bag deactivation (PAD) indicator electrical connector. 5. Remove the 2 screws and remove the PAD indicator. 6. To install, reverse the removal procedure. 7. Repower the system. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9549 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9550 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9551 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9552 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9553 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9554 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9555 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9556 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9557 Cigarette Lighter: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9558 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9559 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9560 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9561 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9562 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9563 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9564 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9565 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9566 Cigarette Lighter: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 44-1 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams By Number. See: Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9567 Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. See: Diagrams/Components/Component Location Views Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams C909 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Vehicle Demagnetizing Compass: Service and Repair Vehicle Demagnetizing VEHICLE DEMAGNETIZING CAUTION: During demagnetizing, the demagnetizer coil pulls 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 4 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. Carry out the compass zone adjustment procedure. See: Compass Zone Adjustment 3. Carry out the compass calibration adjustment procedure. See: Compass Calibration Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Vehicle Demagnetizing > Page 9573 Compass: Service and Repair Compass Zone Adjustment With Message Center COMPASS ZONE ADJUSTMENT With Message Center 1. Turn the ignition switch to the ON position. 2. Start the engine. 3. From the SETUP menu, select compass zone. 4. Determine which magnetic zone you are in for your geographic location. 5. Press the RESET button until the message center display changes to show the current zone setting. 6. Press the RESET button repeatedly until the correct zone setting for your geographic location is displayed. 7. Wait 4 seconds when the correct zone is chosen. Without Message Center COMPASS ZONE ADJUSTMENT Without Message Center 1. Turn the ignition switch to the ON position. 2. Locate the reset button on top of the compass sensor located behind the mirror. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Vehicle Demagnetizing > Page 9574 3. Determine which magnetic zone you are in for your geographic location. 4. Press and hold the reset button on the compass module for approximately 4 seconds until COMPASS ZONE XX appears in the instrument cluster display. 5. Continue to press the reset button until the correct zone setting for your geographic location appears in the instrument cluster display. 6. After 4 seconds, ZONE SET appears in the instrument cluster display. The zone is updated. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Vehicle Demagnetizing > Page 9575 Compass: Service and Repair Compass Calibration With Message Center COMPASS CALIBRATION With Message Center 1. 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. Start the vehicle. 2. From the SETUP menu, press the SETUP button to select the compass calibration function. 3. Press the RESET button. 4. NOTE: - It will take up to 5 circles to complete the calibration. - If not calibrated within 3 minutes or if the RESET button is pressed during CIRCLE SLOWLY TO CALIBRATE, CIRCLE SLOWLY TO CALIBRATE changes to CAL and the calibration process must start over. Slowly drive the vehicle in a circle at no more than 5 km/h (3 mph) until CIRCLE SLOWLY TO CALIBRATE changes to CALIBRATION COMPLETED in the message center. Without Message Center COMPASS CALIBRATION Without Message Center 1. 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. Start the vehicle. 2. Locate the reset button on top of the compass sensor located behind the mirror. 3. Press and hold the reset button on the compass module for approximately 8 seconds and release. 4. NOTE: - It will take up to 5 circles to complete the calibration. - If not calibrated within 3 minutes or if the reset button is pressed during CIRCLE SLOWLY TO CALIBRATE, CIRCLE SLOWLY TO CALIBRATE changes to CAL and the calibration process must start over. Slowly drive the vehicle in a circle at no more than 5 km/h (3 mph) until CIRCLE SLOWLY TO CALIBRATE changes to CALIBRATION COMPLETE in the instrument cluster display. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Depowering and Repowering SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING Special Tool(s) Special Tool(s) Depowering 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. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the electrical connector on a safety canopy module. Doing so can result in safety canopy deployment. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a SRS component is being serviced, the SRS must be depowered. - 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. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box (SJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse 17 (10A) from the SJB. 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 switch to OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or installing any front or side air bag supplemental restraint system (SRS) components and before servicing, installing, 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 front impact severity sensors are located on the radiator support bracket above the lower front splash shield. The front door side impact sensors are located in the first row doors, behind the door trim panel. The C-pillar side impact sensors (if equipped) are located on the C-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). Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9581 remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install RCM fuse 17 (10A) to the SJB and close the cover. 4. 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. 5. Prove out the SRS as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch 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 6 seconds and then turn off. If an air bag SRS fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag indicator might not light 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 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 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous diagnostic trouble codes (DTCs) from the RCM and occupant classification sensor (OCS) module using a scan tool. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9582 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Deactivation and Reactivation SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION Special Tool(s) Special Tool(s) Deactivation 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. - Never probe the connectors on the safety canopy module. Doing so can result in safety canopy deployment, which can result in personal injury. - The safety belt pretensioner and adaptive load limiting retractor are pyrotechnic devices. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner/adaptive load limiting retractor. Never probe a pretensioner or adaptive load limiting retractor electrical connector. Doing so could result in pretensioner, adaptive load limiting retractor or air bag deployment and could result in personal injury. - 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a SRS component is being serviced, the SRS must be depowered. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9583 - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a SRS fault. - 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 smart junction box (SJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse 17 (10A) from the SJB. 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 front impact severity sensors are located on the radiator support bracket above the lower front splash shield. The front door side impact sensors are located in the first row doors, behind the door trim panel. The C-pillar side impact sensors (if equipped) are located on the C-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). Disconnect the battery ground cable and wait at least one minute. 7. Remove the 2 driver air bag module bolts (1 shown). 8. NOTE: Note the position of the 3 driver air bag module wiring connectors for installation. Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag module. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9584 9. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of the steering column. 10. Open and lower the glove compartment door. 11. Detach the wiring retainer, remove the 4 bolts and the passenger air bag module heat shield. 12. NOTE: Deactivate the passenger air bag module as shown, the canister vent and adaptive tether squibs do not require deactivation. Through the glove compartment opening, disconnect the LH side passenger air bag module electrical connector. 13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector on the LH side. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9585 14. From under the rear of the passenger seat, detach the passenger seat side air bag module electrical connector from the seat track bracket. Then slide and disengage the passenger seat side air bag module electrical connector locking clip, and then release the tab and disconnect the passenger seat side air bag module electrical connector. 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat side air bag module electrical connector. Vehicles without safety canopy modules 16. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy bridge resistor from the safety canopy electrical connector. If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the RCM. If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low resistance fault will be generated by the RCM. Explorer and Mountaineer vehicles with safety canopy modules 17. Release and position aside the passenger side C-pillar trim panel. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9586 18. Disconnect the passenger side safety canopy module electrical connector. 19. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. 20. Release and position aside the driver side C-pillar trim panel. 21. Disconnect the driver side safety canopy module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9587 22. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. Explorer Sport Trac vehicles with safety canopy modules 23. Remove the driver and passenger side upper C-pillar trim panels. 24. Disconnect the passenger side safety canopy module electrical connector. 25. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. 26. Disconnect the driver side safety canopy module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9588 27. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. All vehicles 28. From under the rear of the driver seat, slide and disengage the driver seat side air bag module electrical connector locking clip, and then release the tab and disconnect the driver seat side air bag module electrical connector. 29. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air bag module electrical connector. 30. Install the RCM fuse 17 (10A) to the SJB. 31. Connect the battery ground cable. Reactivation All vehicles 1. Remove the RCM fuse 17 (10A) from the SJB. 2. Disconnect the battery ground cable and wait at least one minute. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9589 3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat side air bag module electrical connector. 4. Connect the driver seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Explorer Sport Trac vehicles with safety canopy modules 5. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 6. Connect the driver side safety canopy module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9590 7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 8. Connect the passenger side safety canopy module electrical connector. 9. Install the driver and passenger upper C-pillar trim panels. Explorer and Mountaineer vehicles with safety canopy modules 10. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 11. Connect the driver side safety canopy module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9591 12. Install the driver side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. 13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 14. Connect the passenger side safety canopy module electrical connector. 15. Install the passenger side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. All vehicles Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9592 16. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat side air bag module electrical connector. 17. Connect the passenger seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Then attach the passenger seat side air bag module electrical connector to the seat track bracket. 18. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector on the LH side. 19. Connect the LH side passenger air bag module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9593 20. Install the passenger air bag module heat shield and the 4 bolts. Attach the wiring retainer. 21. Close glove compartment door. 22. Remove the restraint system diagnostic tools from the clockspring electrical connectors at the top of the steering column. 23. CAUTION: The clockspring electrical connectors are unique and cannot be connected to the driver air bag module in the wrong position. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Connect the driver air bag module electrical connectors as noted in removal. 24. Install the 2 driver air bag module bolts (1 shown). - Tighten to 7 Nm (62 lb-in). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9594 25. 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. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 26. Turn the ignition switch from OFF to ON. 27. Install the RCM fuse 17 (10A) to the SJB and install the cover. 28. 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. 29. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the switch 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 6 seconds and then turn off. If an air bag SRS fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag indicator might not light 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 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 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and occupant classification sensor (OCS) module using a scan tool. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Testing and Inspection > Page 9598 Dimmer Switch: Service and Repair INSTRUMENT PANEL DIMMER SWITCH Removal and Installation 1. Remove the driver side register. 2. Remove the headlamp switch and bezel as an assembly. - Disconnect the electrical connectors. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Testing and Inspection > Page 9599 3. Release the 2 tabs and remove the instrument panel dimmer switch. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front View 151-21 (Driver Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 9604 View 151-22 (Passenger Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 9605 View 151-24 (Left Rear Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 9606 View 151-23 (Right Rear Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 9607 Door Switch: Locations View 151-21 (Driver Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 9608 View 151-22 (Passenger Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 9609 View 151-24 (Left Rear Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 9610 View 151-23 (Right Rear Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 9611 View 151-25 (Liftgate) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 9612 View 151-25 (Liftgate) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch C479 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 9615 C478 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 9616 C526 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 9617 C602 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 9618 Door Switch: Diagrams C479 C478 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 9619 C526 C602 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 9620 C715 C820 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Locations View 151-11 (behind Dash Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Locations > Page 9624 C253 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Locations > Page 9625 Driver/Vehicle Information Display: Description and Operation INFORMATION AND MESSAGE CENTER The message center is a liquid crystal display (LCD), integrated into the instrument cluster. The message center functions are controlled by the TRIP/RESET button on base instrument clusters, and by the message center switches on high series instrument clusters. The base series instrument cluster message center has a display format of 2 lines x 12 characters, and the high series instrument cluster message center has a display format of 4 lines x 12 characters. The message center displays important vehicle information by constantly monitoring different vehicle systems. The message center notifies the driver of a potential vehicle problem by displaying a warning message pertaining to the system in which a fault has been detected. Refer to the Owner's Literature for operating instructions. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Driver/Vehicle Information Display: Initial Inspection and Diagnostic Overview Inspection and Verification INSPECTION AND VERIFICATION 1. Verify the customer concern. Visual Inspection Chart 2. Visually inspect for obvious signs of mechanical or electrical damage. 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. NOTE: Make sure to use the latest scan tool software release. If the cause is not visually evident, connect the scan tool to the data link connector (DLC). 5. NOTE: The vehicle communication module (VCM) LED prove-out confirms power and ground from the DLC are provided to the VCM. If the scan tool does not communicate with the VCM: Check the VCM connection to the vehicle. - Check the scan tool connection to the VCM. - Refer to Information Bus (Module Communications Network), No Power To The Scan Tool, to diagnose no communication with the scan tool. 6. If the scan tool does not communicate with the vehicle: - Verify the ignition key is in the ON position. - Verify the scan tool operation with a known good vehicle. - Refer to Information Bus (Module Communications Network) to diagnose no response from the powertrain control module (PCM). 7. Carry out the network test: - If the scan tool responds with no communication for one or more modules, refer to Information Bus (Module Communications Network). - If the network test passes, retrieve and record the continuous memory DTCs. 8. Clear the continuous DTCs and carry out the self-test diagnostics for the instrument cluster. 9. If the DTCs retrieved are related to the concern, go to the Instrument Cluster Diagnostic Trouble Code (DTC) Chart. For all other DTCs, refer to Body Control Systems (Multifunction Electronic Control Module). See: Diagnostic Trouble Code Descriptions 10. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Principles of Operation PRINCIPLES OF OPERATION The message center electronic functions use both hardwired inputs and the controller area network (CAN) to transmit and receive information. It is very important to understand: - where the input (command) originates. - all the information (messages) necessary in order for a feature to operate. - which module(s) receive(s) the input or command message. - if the module which received the input (message) controls the output of the feature, or if it outputs a message over the CAN circuit to another module. - which module controls the output of the feature. The message center provides the following features: - Information displays - Setup displays - System check messages - Warning messages Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9628 The message center information can be selected through the TRIP/RESET button (base cluster) and by the INFO, SETUP, and RESET buttons (high series cluster). Information Displays (Base Instrument Cluster) The information displays are non-timed modes. The selected mode remains on until the driver presses a message center switch to change the mode, or until it is overridden by another mode. The information display modes are: Odometer/trip odometer, compass headings - Distance to empty - Average fuel economy - Setup menu Information Displays (High Series Instrument Cluster) The information displays are non-timed modes. The selected mode remains on until the driver presses a message center switch to change the mode, or until it is overridden by another mode. The information display modes are: Odometer/trip odometer, compass headings, outside air temperature display (with dual electronic automatic temperature control) - Distance to empty - Average fuel economy - Instantaneous fuel economy - Fuel used - Trip elapsed drive time - Blank Setup Displays (Base Instrument Cluster) The setup displays are timed modes and terminate after a finite interval. Press the TRIP/RESET button to scroll through the SETUP MENU display sequence. If the TRIP/RESET button is not pressed within 4 seconds, the message center returns to the INFO MENU. The setup display modes are: AWD lock (vehicles equipped with traction control with roll stability control [RSC] only) - System check - Units (English/metric) - Language - Autolamp - Autolock - Auto-unlock - Parking aid - Oil life start value Setup Displays (High Series Instrument Cluster) The setup displays are timed modes and terminate after a finite interval. Press the SETUP button for the following displays: AWD lock (vehicles equipped with traction control with roll stability control [RSC] only) - System check - Units (English/metric) - Language - Autolamp - Autolock - Auto-unlock - Running boards (if equipped) - Easy entry/exit seat - Parking aid - Compass zone - Compass calibration - Oil life start value System Check Displays Selecting this function from the SETUP MENU causes the message center to cycle through each of the systems being monitored. For each of the monitored systems, the message center indicates either an OK message or a warning message for 2 seconds. For base instrument clusters, the TRIP/RESET button must be held down after pressing the TRIP/RESET button to cycle the messages through each of the systems being monitored. For high series instrument clusters, pressing the RESET control switch cycles the message center through each of the systems being monitored. The system check report is as follows: OIL LIFE RESET - CHARGING SYSTEM - WASHER FLUID - DOOR AJAR - EXTERIOR LAMPS - BRAKE FLUID LEVEL - PARK BRAKE - FUEL LEVEL Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9629 System Warnings The system warnings alert the operator to possible problems or malfunctions in the vehicle operating systems. The message center displays the last selected feature if there are no more warning messages. This allows the operator full functionality of the message center after acknowledgement of the warning message by pressing the RESET button and clearing the message. The warning messages are divided into 4 categories: They cannot be cleared until the condition is corrected. - They reappear on the display 10 minutes from the reset if the condition has not been corrected. - They do not reappear until an ignition OFF-ON cycle has been completed. - They reappear if the condition clears then reoccurs within the same ignition ON-OFF cycle. The warning displays that cannot be reset are: DOOR AJAR - CLEAR OBJECTS BY PASS SEAT The warning messages that reoccur after 10 minutes are: CHECK CHARGING SYSTEM - FUEL LEVEL LOW - PARK BRAKE ENGAGED - CHECK BRAKE SYSTEM The warning messages that display whenever the ignition switch is turned from the OFF position to the ON position are: CHECK PARK AID - BRAKE FLUID LEVEL LOW - CHECK HEADLAMP - CHECK HIGHBEAM - CHECK TURN LAMP - WASHER FLUID LOW LEVEL - OIL CHANGE REQUIRED - ENGINE OIL CHANGE SOON The warning messages that return after a condition has cleared then reoccurs within the same ignition ON-OFF cycle are: LIFTGATE/GLASS AJAR - LOW TIRE PRESSURE - TIRE MONITOR FAULT - TIRE SENSOR FAULT - TRAIN TIRES - TIRES TRAINED - TIRES NOT TRAINED Outside Air Temperature Sensor (Base Instrument Cluster without Electronic Automatic Temperature Control [EATC]) The base instrument cluster receives the outside air temperature data from the outside air temperature sensor. This data is then displayed on the message center. The outside air temperature sensor is located on the radiator core support behind the front grill assembly and is fastened with a pin-type retainer. If equipped with a high series instrument cluster, the outside air temperature data from the outside air temperature sensor is displayed in the electronic automatic temperature control (EATC) module. Compass The compass heading is displayed as one of N, NE, E, SE, S, SW, W and NW in the message center display. The compass reading may be affected when you drive near large buildings, bridges, power lines and powerful broadcast antenna. Magnetic or metallic objects placed in, on or near the vehicle may also affect compass accuracy. The compass sensor module is mounted behind the interior rear view mirror. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9630 B1255-B2097 / U2013 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9631 Driver/Vehicle Information Display: Symptom Related Diagnostic Procedures Symptom Chart (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9632 Symptom Chart (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9633 Symptom Chart (Part 3) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9634 Symptom Chart (Part 4) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9635 Symptom Chart (Part 5) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9636 Driver/Vehicle Information Display: Pinpoint Tests Test A: The Message Center Is Not Operating Correctly PINPOINT TEST A: THE MESSAGE CENTER IS NOT OPERATING CORRECTLY (HIGH SERIES INSTRUMENT CLUSTER) A1 A2 Normal Operation The message center functionality is controlled through the message center switch, which is hardwired to the instrument cluster through circuits CMC29 (GN/VT) and RMC32 (GN/BU). Possible Causes - Message center switch - Instrument cluster Test B: The Compass Is Inoperative PINPOINT TEST B: THE COMPASS IS INOPERATIVE. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9637 B1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9638 B2-B3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9639 B4 Normal Operation The compass sensor module receives voltage from the smart junction box (SJB) through circuit CBP18 (GY/OG) and is grounded through circuit GD143 (BK/VT). The compass sensor module communicates the vehicle direction to the instrument cluster, which is displayed in the message center. The compass sensor module uses circuits VMC30 (BU/GY) and VMC31 (YE/GN) to communicate to the instrument cluster. DTC B2097 - is a continuous memory DTC that sets in the instrument cluster if the data received from the compass module is invalid. DTC U2013 - is a continuous and on-demand DTC that sets if the instrument cluster fails to receive a response from the compass module after 4 consecutive attempts. Possible Causes - Fuse - Circuit CBP18 (GY/OG) open - Circuit GD143 (BK/VT) open - Circuit VMC30 (BU/GY) open or short to ground - Circuit VMC31 (YE/GN) open or short to ground -- Compass sensor module Test C: The Compass Is Inaccurate PINPOINT TEST C: THE COMPASS IS INACCURATE C1-C2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9640 C2 Normal Operation The compass sensor module communicates the vehicle direction to the instrument cluster to display in the message center. Possible Causes - Compass out of calibration - Zone setting - Vehicle is magnetized - Compass sensor module Test D: The Message Center Switch Does Not Operate Correctly PINPOINT TEST D: THE MESSAGE CENTER SWITCH DOES NOT OPERATE CORRECTLY (HIGH SERIES INSTRUMENT CLUSTER) D1-D2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9641 D2-D4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9642 D4-D5 Normal Operation The message center switch uses circuit CMC29 (GN/VT) to communicate the requested switch function to the instrument cluster message center. The message center switch is grounded through circuit RMC32 (GN/BU). Each message center switch uses a different resistance value allowing the instrument cluster to determine which switch is pressed. Possible Causes - Circuit CMC29 (GN/VT) open, short to ground or voltage - Circuit RMC32 (GN/BU) open - Message center switch - Instrument cluster Test E: The Outside Air Temperature Display Does Not Operate Correctly PINPOINT TEST E: THE OUTSIDE AIR TEMPERATURE DISPLAY DOES NOT OPERATE CORRECTLY Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9643 E1-E3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9644 E3-E5 NOTE: The outside air temperature display is only available in base instrument clusters without electronic automatic temperature control (EATC). Normal Operation The outside air temperature sensor is hardwired to the instrument cluster through circuits VH407 (YE/GN) and RMC32 (GN/BU). The message center displays the outside air temperature upon receipt of the outside air temperature data. DTC B1255 - is a continuous and on-demand DTC that sets if the instrument cluster detects an open on the outside air temperature sensor input circuit VH407 (YE/GN). If the instrument cluster detects an open on the outside air temperature input, the instrument cluster defaults the display to 23.5° Celsius (75°F). DTC B1257 - is a continuous and on-demand DTC that sets if the instrument cluster detects a short to ground on the outside air temperature sensor input circuit VH407 (YE/GN). If the instrument cluster detects a short to ground on the outside air temperature input, the instrument cluster defaults Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9645 the display to 23.5°Celsius (75°F). Possible Causes - Circuit VH407 (YE/GN) open or short to ground - Circuit RMC32 (GN/BU) open - Ambient air temperature sensor - Instrument cluster Test F: The Washer Fluid Low Level Warning Is Inoperative PINPOINT TEST F: THE WASHER FLUID LOW LEVEL WARNING IS INOPERATIVE F1-F2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9646 F3-F6 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9647 F6-F7 Normal Operation The instrument cluster is hardwired to the low washer fluid switch (part of the windshield washer reservoir) through circuit CMC20 (VT). The low washer fluid switch closes when the washer fluid level is approximately 1/3 full, providing a ground to the instrument cluster through circuit GD108 (BK/VT) and turning on the WASHER FLUID LOW LEVEL warning. When the washer fluid is above the low level, the low washer fluid switch opens, removing the ground to the instrument cluster, and the WASHER FLUID LOW LEVEL warning turns off. Possible Causes - Circuit GD108 (BK/VT) open - Circuit CMC20 (VT) open or short to ground - Washer fluid level switch (part of the windshield washer reservoir) - Instrument cluster Test G: The Check Charging System Warning Is Inoperative PINPOINT TEST G: THE CHECK CHARGING SYSTEM WARNING IS INOPERATIVE G1-G2 Normal Operation The charging system warning indicator is controlled by the instrument cluster based upon data received from the powertrain control module (PCM) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9648 over the high speed controller area network (HS-CAN). Possible Causes - Charging system - Instrument cluster Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures Driver/Vehicle Information Display: Procedures Message Center Cluster OIL LIFE RESET - MESSAGE CENTER CLUSTER NOTE: The oil life calculation is set at a maximum of approximately 8,000 km (5,000 miles) or 180 days. 1. Press and release the SETUP button until the message center displays PRESS RESET TO BEGIN SYSTEM CHECK. 2. Press and release the RESET button until the message center displays HOLD RESET IF NEW OIL. 3. Press and hold the RESET button for 2 seconds and release to reset the oil life to 100%. 4. The message center displays SETUP MENU HOLD RESET. Base Instrument Cluster OIL LIFE RESET - BASE INSTRUMENT CLUSTER NOTE: Oil life calculation is set at a maximum of approximately 8,000 km (5,000 miles) or 180 days. 1. Press and release the TRIP/RESET button until the message center displays SETUP MENU HOLD RESET. 2. Press and hold the TRIP/RESET button for 2 seconds until the message center displays RESET FOR SYSTEM CHECK. 3. Press and hold the TRIP/RESET button for 2 seconds until the message center displays OIL LIFE xx% RESET IF NEW. 4. Press and release the TRIP/RESET button until the message center displays HOLD RESET IF NEW OIL. 5. Press and hold the TRIP/RESET button for 2 seconds and release to reset the oil life to 100%. 6. Message center briefly displays OIL CHANGE SET TO 100%. Message Center Cluster OIL LIFE START VALUE - MESSAGE CENTER CLUSTER NOTE: The oil life start value is used to reset the oil life value back to the maximum of approximately 8,000 km (5,000 miles) if the value was previously changed or to lower the value from the maximum (8,000 km [5,000 miles]) in 10% increments down to 10%. 1. Press and release the SETUP button until the message center displays OIL LIFE START VALUE SET TO XX%. 2. Press and release the RESET button to lower the percentage by 10% (down to 10%) for each button press or return the value to 100%. Base Instrument Cluster OIL LIFE START VALUE - BASE INSTRUMENT CLUSTER NOTE: The oil life start value is used to reset the oil life value back to the maximum of approximately 8,000 km (5,000 miles) if the value was previously changed or to lower the value from the maximum (8,000 km [5,000 miles]) in 10% increments down to 10%. 1. Press and release the TRIP/RESET button until the message center displays SETUP MENU HOLD RESET. 2. Press and hold the TRIP/RESET button for 2 seconds until the message center displays RESET FOR SYSTEM CHECK. 3. Press and release the TRIP/RESET button until the message center displays OIL LIFE SET TO XX%. 4. Press and hold the TRIP/RESET button for 2 seconds to lower the percentage by 10% (down to 10%) for each button press-and-hold or return the value to 100%. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 9651 Driver/Vehicle Information Display: Removal and Replacement MESSAGE CENTER SWITCH Removal and Installation 1. Remove the instrument panel center finish panel. 2. Press the retaining tabs and remove the message center switch. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Page 9652 Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > Customer Interest for Fuel Distance/Mileage Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets Fuel Distance/Mileage Module: Customer Interest Instruments - Trip Odometers/Fuel Economy Resets TSB 09-21-7 11/02/09 TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS UNINTENTIONALLY FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally. This condition may occur if there is an intermittent electrical connection on the power feed to the cluster or if the reset button on the 3-button message center assembly is momentarily touched. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. With the key in the On position, display the trip odometer mileage. 2. Start the vehicle. 3. Cycle the key back Off and restart the vehicle. 4. Verify whether the trip mileage reset or not. 5. If not, proceed to Step 10. 6. If it reset, turn the key Off and remove the key from the ignition. 7. Activate the emergency flashers. 8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal fuse and wiring diagnostics to correct the power feed circuit. 9. Verify repair and proceed to Step 10. 10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release 63.07 and higher. This new calibration is not included in the VCM 2009.9 DVD. Calibration files may also be obtained at the website. NOTE REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT RESOLVE THIS ISSUE. 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 092107A 2006-2010 Explorer, 0.3 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > Customer Interest for Fuel Distance/Mileage Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 9661 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Distance/Mileage Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets Fuel Distance/Mileage Module: All Technical Service Bulletins Instruments - Trip Odometers/Fuel Economy Resets TSB 09-21-7 11/02/09 TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS UNINTENTIONALLY FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally. This condition may occur if there is an intermittent electrical connection on the power feed to the cluster or if the reset button on the 3-button message center assembly is momentarily touched. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. With the key in the On position, display the trip odometer mileage. 2. Start the vehicle. 3. Cycle the key back Off and restart the vehicle. 4. Verify whether the trip mileage reset or not. 5. If not, proceed to Step 10. 6. If it reset, turn the key Off and remove the key from the ignition. 7. Activate the emergency flashers. 8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal fuse and wiring diagnostics to correct the power feed circuit. 9. Verify repair and proceed to Step 10. 10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release 63.07 and higher. This new calibration is not included in the VCM 2009.9 DVD. Calibration files may also be obtained at the website. NOTE REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT RESOLVE THIS ISSUE. 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 092107A 2006-2010 Explorer, 0.3 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Distance/Mileage Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 9667 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Filler Cap Warning Indicator > Component Information > Description and Operation Fuel Filler Cap Warning Indicator: Description and Operation CHECK FUEL CAP INDICATOR The check fuel cap indicator is a communications network message sent by the PCM. The PCM sends the message to illuminate the lamp when the strategy determines that there is a failure in the vapor management system due to the fuel filler cap not being sealed correctly. This would be detected by the inability to pull vacuum in the fuel tank, after a fueling event. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 Fuel Gauge: Customer Interest Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 TSB 06-17-10 09/04/06 MIL ON WITH DTC P0463 OR ERRATIC FUEL GAUGE OPERATION FORD: 2004-2007 Explorer MERCURY: 2004-2007 Mountaineer This article supersedes TSB 06-16-7 to update the Service Procedure. ISSUE Some 2004-2007 Explorer 4dr/Mountaineer vehicles may exhibit the malfunction indicator lamp (MIL) on with diagnostic trouble code (DTC) P0463 or an erratic fuel gauge concern. This could be from sulphur contamination in the fuel, causing an open or high resistance on the fuel sender card. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. For vehicles with customer symptom of erratic fuel gauge operation (with no MIL on), proceed to Step 1a. For vehicles with a customer symptom including the MIL on, proceed to Step 1b. If unable to verify the concern, do not continue with this TSB. a. Follow the appropriate pinpoint test (PPT) for "Fuel Gauge Inaccurate" in Workshop Manual (WSM), Section 413-01. If PPT test results lead to fuel pump module replacement, proceed to Step 2. If PPT test results isolate any problem other than fuel pump module replacement, repair as indicated and do not continue with this TSB. b. Install diagnostic scan tool to retrieve DTCs. If DTC P0463 is retrieved, proceed to Step 2. If DTC P0463 is not retrieved, this TSB does not apply, follow normal WSM diagnostics. 2. Remove fuel tank per WSM, Section 310-01. 3. Remove fuel pump assembly from fuel tank per WSM, Section 310-01. See Figure 1 (Chart) to determine if a kit (contains a fuel level sensor assembly, a wire harness and heat shrink tube) or fuel pump assembly is required for repair. For vehicles that can be serviced with a kit go to Step 4. For vehicles that require fuel pump assembly replacement, go to Step 12. 4. Remove the fuel level sensor assembly (sender card/float rod assembly) from the fuel pump assembly per WSM, Section 310-01. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 9679 5. Detach electrical connector from fuel pump housing (Figure 2). 6. Remove wiring harness from the fuel pump assembly flange by depressing the retaining fingers on the harness connector at bottom of flange and pushing upward out of flange (Figure 3). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 9680 7. Install new wiring harness by feeding wires through flange hole and inserting harness connector into flange until an audible click is heard. Check for proper retention. 8. Re-attach electrical connector harness to fuel pump housing. Prior to making the connection place one loop in the pump wires away from the convoluted feed tube (Figure 4). 9. Re-attach the signal wire (yellow) on the harness to the signal wire (yellow) on the replacement fuel level sensor assembly per WSM, Section 310-01 (Figure 5). 10. Wrap the ground wire one time around the signal wire and attach the ground wire terminal to the terminal on the fuel level sensor assembly. Check for proper retention. NOTE THE GROUND WIRE MUST BE WRAPPED AROUND THE SIGNAL WIRE, AS DESCRIBED IN STEP 10, TO PREVENT POTENTIAL INTERFERENCE WITH THE FLOAT ROD ARM. 11. Re-attach the fuel level sensor assembly to the fuel pump housing, making sure that both the signal wire and the ground wire are routed through the Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 9681 gap between the fuel level sensor assembly and fuel pump bracket. Torque the fastener at the bottom of the fuel level sensor assembly to 1 N.m (9 lb-in). 12. Re-install fuel pump assembly into fuel tank per WSM, Section 310-01. NOTE TAKE CARE NOT TO DAMAGE/BEND FLOAT ROD OR SENDER CARD DURING INSTALLATION OF FUEL PUMP ASSEMBLY. 13. Re-install fuel tank per WSM, Section 310-01. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 061710A 2004-2007 2.9 Hrs. Explorer/Mountaineer: Diagnose And Replace The Fuel Gauge Tank Unit (Do Not Use With 9275D, 9275A, 9002A) DEALER CODING CONDITION BASIC PART NO. CODE 9A299 28 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 Fuel Gauge: All Technical Service Bulletins Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 TSB 06-17-10 09/04/06 MIL ON WITH DTC P0463 OR ERRATIC FUEL GAUGE OPERATION FORD: 2004-2007 Explorer MERCURY: 2004-2007 Mountaineer This article supersedes TSB 06-16-7 to update the Service Procedure. ISSUE Some 2004-2007 Explorer 4dr/Mountaineer vehicles may exhibit the malfunction indicator lamp (MIL) on with diagnostic trouble code (DTC) P0463 or an erratic fuel gauge concern. This could be from sulphur contamination in the fuel, causing an open or high resistance on the fuel sender card. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. For vehicles with customer symptom of erratic fuel gauge operation (with no MIL on), proceed to Step 1a. For vehicles with a customer symptom including the MIL on, proceed to Step 1b. If unable to verify the concern, do not continue with this TSB. a. Follow the appropriate pinpoint test (PPT) for "Fuel Gauge Inaccurate" in Workshop Manual (WSM), Section 413-01. If PPT test results lead to fuel pump module replacement, proceed to Step 2. If PPT test results isolate any problem other than fuel pump module replacement, repair as indicated and do not continue with this TSB. b. Install diagnostic scan tool to retrieve DTCs. If DTC P0463 is retrieved, proceed to Step 2. If DTC P0463 is not retrieved, this TSB does not apply, follow normal WSM diagnostics. 2. Remove fuel tank per WSM, Section 310-01. 3. Remove fuel pump assembly from fuel tank per WSM, Section 310-01. See Figure 1 (Chart) to determine if a kit (contains a fuel level sensor assembly, a wire harness and heat shrink tube) or fuel pump assembly is required for repair. For vehicles that can be serviced with a kit go to Step 4. For vehicles that require fuel pump assembly replacement, go to Step 12. 4. Remove the fuel level sensor assembly (sender card/float rod assembly) from the fuel pump assembly per WSM, Section 310-01. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 9687 5. Detach electrical connector from fuel pump housing (Figure 2). 6. Remove wiring harness from the fuel pump assembly flange by depressing the retaining fingers on the harness connector at bottom of flange and pushing upward out of flange (Figure 3). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 9688 7. Install new wiring harness by feeding wires through flange hole and inserting harness connector into flange until an audible click is heard. Check for proper retention. 8. Re-attach electrical connector harness to fuel pump housing. Prior to making the connection place one loop in the pump wires away from the convoluted feed tube (Figure 4). 9. Re-attach the signal wire (yellow) on the harness to the signal wire (yellow) on the replacement fuel level sensor assembly per WSM, Section 310-01 (Figure 5). 10. Wrap the ground wire one time around the signal wire and attach the ground wire terminal to the terminal on the fuel level sensor assembly. Check for proper retention. NOTE THE GROUND WIRE MUST BE WRAPPED AROUND THE SIGNAL WIRE, AS DESCRIBED IN STEP 10, TO PREVENT POTENTIAL INTERFERENCE WITH THE FLOAT ROD ARM. 11. Re-attach the fuel level sensor assembly to the fuel pump housing, making sure that both the signal wire and the ground wire are routed through the Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 9689 gap between the fuel level sensor assembly and fuel pump bracket. Torque the fastener at the bottom of the fuel level sensor assembly to 1 N.m (9 lb-in). 12. Re-install fuel pump assembly into fuel tank per WSM, Section 310-01. NOTE TAKE CARE NOT TO DAMAGE/BEND FLOAT ROD OR SENDER CARD DURING INSTALLATION OF FUEL PUMP ASSEMBLY. 13. Re-install fuel tank per WSM, Section 310-01. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 061710A 2004-2007 2.9 Hrs. Explorer/Mountaineer: Diagnose And Replace The Fuel Gauge Tank Unit (Do Not Use With 9275D, 9275A, 9002A) DEALER CODING CONDITION BASIC PART NO. CODE 9A299 28 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9692 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9693 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9694 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9695 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9696 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9697 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9698 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9699 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9700 Fuel Gauge: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9701 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9702 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9703 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9704 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9705 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9706 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9707 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 9708 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 Fuel Gauge Sender: Customer Interest Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 TSB 06-17-10 09/04/06 MIL ON WITH DTC P0463 OR ERRATIC FUEL GAUGE OPERATION FORD: 2004-2007 Explorer MERCURY: 2004-2007 Mountaineer This article supersedes TSB 06-16-7 to update the Service Procedure. ISSUE Some 2004-2007 Explorer 4dr/Mountaineer vehicles may exhibit the malfunction indicator lamp (MIL) on with diagnostic trouble code (DTC) P0463 or an erratic fuel gauge concern. This could be from sulphur contamination in the fuel, causing an open or high resistance on the fuel sender card. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. For vehicles with customer symptom of erratic fuel gauge operation (with no MIL on), proceed to Step 1a. For vehicles with a customer symptom including the MIL on, proceed to Step 1b. If unable to verify the concern, do not continue with this TSB. a. Follow the appropriate pinpoint test (PPT) for "Fuel Gauge Inaccurate" in Workshop Manual (WSM), Section 413-01. If PPT test results lead to fuel pump module replacement, proceed to Step 2. If PPT test results isolate any problem other than fuel pump module replacement, repair as indicated and do not continue with this TSB. b. Install diagnostic scan tool to retrieve DTCs. If DTC P0463 is retrieved, proceed to Step 2. If DTC P0463 is not retrieved, this TSB does not apply, follow normal WSM diagnostics. 2. Remove fuel tank per WSM, Section 310-01. 3. Remove fuel pump assembly from fuel tank per WSM, Section 310-01. See Figure 1 (Chart) to determine if a kit (contains a fuel level sensor assembly, a wire harness and heat shrink tube) or fuel pump assembly is required for repair. For vehicles that can be serviced with a kit go to Step 4. For vehicles that require fuel pump assembly replacement, go to Step 12. 4. Remove the fuel level sensor assembly (sender card/float rod assembly) from the fuel pump assembly per WSM, Section 310-01. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 9717 5. Detach electrical connector from fuel pump housing (Figure 2). 6. Remove wiring harness from the fuel pump assembly flange by depressing the retaining fingers on the harness connector at bottom of flange and pushing upward out of flange (Figure 3). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 9718 7. Install new wiring harness by feeding wires through flange hole and inserting harness connector into flange until an audible click is heard. Check for proper retention. 8. Re-attach electrical connector harness to fuel pump housing. Prior to making the connection place one loop in the pump wires away from the convoluted feed tube (Figure 4). 9. Re-attach the signal wire (yellow) on the harness to the signal wire (yellow) on the replacement fuel level sensor assembly per WSM, Section 310-01 (Figure 5). 10. Wrap the ground wire one time around the signal wire and attach the ground wire terminal to the terminal on the fuel level sensor assembly. Check for proper retention. NOTE THE GROUND WIRE MUST BE WRAPPED AROUND THE SIGNAL WIRE, AS DESCRIBED IN STEP 10, TO PREVENT POTENTIAL INTERFERENCE WITH THE FLOAT ROD ARM. 11. Re-attach the fuel level sensor assembly to the fuel pump housing, making sure that both the signal wire and the ground wire are routed through the Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 9719 gap between the fuel level sensor assembly and fuel pump bracket. Torque the fastener at the bottom of the fuel level sensor assembly to 1 N.m (9 lb-in). 12. Re-install fuel pump assembly into fuel tank per WSM, Section 310-01. NOTE TAKE CARE NOT TO DAMAGE/BEND FLOAT ROD OR SENDER CARD DURING INSTALLATION OF FUEL PUMP ASSEMBLY. 13. Re-install fuel tank per WSM, Section 310-01. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 061710A 2004-2007 2.9 Hrs. Explorer/Mountaineer: Diagnose And Replace The Fuel Gauge Tank Unit (Do Not Use With 9275D, 9275A, 9002A) DEALER CODING CONDITION BASIC PART NO. CODE 9A299 28 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 Fuel Gauge Sender: All Technical Service Bulletins Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 TSB 06-17-10 09/04/06 MIL ON WITH DTC P0463 OR ERRATIC FUEL GAUGE OPERATION FORD: 2004-2007 Explorer MERCURY: 2004-2007 Mountaineer This article supersedes TSB 06-16-7 to update the Service Procedure. ISSUE Some 2004-2007 Explorer 4dr/Mountaineer vehicles may exhibit the malfunction indicator lamp (MIL) on with diagnostic trouble code (DTC) P0463 or an erratic fuel gauge concern. This could be from sulphur contamination in the fuel, causing an open or high resistance on the fuel sender card. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. For vehicles with customer symptom of erratic fuel gauge operation (with no MIL on), proceed to Step 1a. For vehicles with a customer symptom including the MIL on, proceed to Step 1b. If unable to verify the concern, do not continue with this TSB. a. Follow the appropriate pinpoint test (PPT) for "Fuel Gauge Inaccurate" in Workshop Manual (WSM), Section 413-01. If PPT test results lead to fuel pump module replacement, proceed to Step 2. If PPT test results isolate any problem other than fuel pump module replacement, repair as indicated and do not continue with this TSB. b. Install diagnostic scan tool to retrieve DTCs. If DTC P0463 is retrieved, proceed to Step 2. If DTC P0463 is not retrieved, this TSB does not apply, follow normal WSM diagnostics. 2. Remove fuel tank per WSM, Section 310-01. 3. Remove fuel pump assembly from fuel tank per WSM, Section 310-01. See Figure 1 (Chart) to determine if a kit (contains a fuel level sensor assembly, a wire harness and heat shrink tube) or fuel pump assembly is required for repair. For vehicles that can be serviced with a kit go to Step 4. For vehicles that require fuel pump assembly replacement, go to Step 12. 4. Remove the fuel level sensor assembly (sender card/float rod assembly) from the fuel pump assembly per WSM, Section 310-01. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 9725 5. Detach electrical connector from fuel pump housing (Figure 2). 6. Remove wiring harness from the fuel pump assembly flange by depressing the retaining fingers on the harness connector at bottom of flange and pushing upward out of flange (Figure 3). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 9726 7. Install new wiring harness by feeding wires through flange hole and inserting harness connector into flange until an audible click is heard. Check for proper retention. 8. Re-attach electrical connector harness to fuel pump housing. Prior to making the connection place one loop in the pump wires away from the convoluted feed tube (Figure 4). 9. Re-attach the signal wire (yellow) on the harness to the signal wire (yellow) on the replacement fuel level sensor assembly per WSM, Section 310-01 (Figure 5). 10. Wrap the ground wire one time around the signal wire and attach the ground wire terminal to the terminal on the fuel level sensor assembly. Check for proper retention. NOTE THE GROUND WIRE MUST BE WRAPPED AROUND THE SIGNAL WIRE, AS DESCRIBED IN STEP 10, TO PREVENT POTENTIAL INTERFERENCE WITH THE FLOAT ROD ARM. 11. Re-attach the fuel level sensor assembly to the fuel pump housing, making sure that both the signal wire and the ground wire are routed through the Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 9727 gap between the fuel level sensor assembly and fuel pump bracket. Torque the fastener at the bottom of the fuel level sensor assembly to 1 N.m (9 lb-in). 12. Re-install fuel pump assembly into fuel tank per WSM, Section 310-01. NOTE TAKE CARE NOT TO DAMAGE/BEND FLOAT ROD OR SENDER CARD DURING INSTALLATION OF FUEL PUMP ASSEMBLY. 13. Re-install fuel tank per WSM, Section 310-01. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 061710A 2004-2007 2.9 Hrs. Explorer/Mountaineer: Diagnose And Replace The Fuel Gauge Tank Unit (Do Not Use With 9275D, 9275A, 9002A) DEALER CODING CONDITION BASIC PART NO. CODE 9A299 28 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 9728 Fuel Gauge Sender: Description and Operation FUEL PUMP (FP) MODULE Typical Electronic Returnless Fuel Pump (FP) Module Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 9729 Typical Mechanical Returnless Fuel Pump (FP) Module The FP module 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. FUEL PUMP (FP) MODULE AND RESERVOIR The FP module is mounted inside the fuel tank in a reservoir. The pump has a discharge check valve that maintains the system pressure after the key has been turned off to minimize starting concerns. The reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low tank fill levels. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 9730 Fuel Gauge Sender: Service and Repair FUEL LEVEL SENSOR Explorer Sport Trac (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 9731 Explorer Sport Trac (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 9732 Explorer/Mountaineer (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 9733 Explorer/Mountaineer (Part 2) All Vehicles (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 9734 All Vehicles (Part 2) Removal 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. 1. Remove the fuel pump. 2. NOTE: Note the routing of the sending unit wire for installation. Remove the heat shrink tube covering the electrical connector. 3. Disconnect the electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 9735 4. Remove the screw and lift up to remove the fuel gauge sending unit. Installation 1. Route the fuel gauge sending unit wire through the center of the fuel pump module. 2. NOTE: - Both fuel gauge sending wires must be routed behind the metal sending unit plate. - The grounding eyelet must be on the front side of the sending unit. Hook the fuel gauge sending unit on the fuel pump module and install the screw through the grounding eyelet and tighten the screw. 3. Slide the heat shrink tube onto the wire harness and connect the electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 9736 4. WARNING: Do not use an open flame to shrink the heat shrink tube, use a heat gun only. Failure to follow these instructions may result in personal injury. Using a heat gun, shrink the heat shrink tube. 5. Install the fuel pump. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Depowering and Repowering SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING Special Tool(s) Special Tool(s) Depowering 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. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the electrical connector on a safety canopy module. Doing so can result in safety canopy deployment. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a SRS component is being serviced, the SRS must be depowered. - 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. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box (SJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse 17 (10A) from the SJB. 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 switch to OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or installing any front or side air bag supplemental restraint system (SRS) components and before servicing, installing, 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 front impact severity sensors are located on the radiator support bracket above the lower front splash shield. The front door side impact sensors are located in the first row doors, behind the door trim panel. The C-pillar side impact sensors (if equipped) are located on the C-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). Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9742 remove could result in injury and possible violation of vehicle safety standards. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install RCM fuse 17 (10A) to the SJB and close the cover. 4. 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. 5. Prove out the SRS as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch 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 6 seconds and then turn off. If an air bag SRS fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag indicator might not light 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 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 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous diagnostic trouble codes (DTCs) from the RCM and occupant classification sensor (OCS) module using a scan tool. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9743 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Deactivation and Reactivation SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION Special Tool(s) Special Tool(s) Deactivation 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. - Never probe the connectors on the safety canopy module. Doing so can result in safety canopy deployment, which can result in personal injury. - The safety belt pretensioner and adaptive load limiting retractor are pyrotechnic devices. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner/adaptive load limiting retractor. Never probe a pretensioner or adaptive load limiting retractor electrical connector. Doing so could result in pretensioner, adaptive load limiting retractor or air bag deployment and could result in personal injury. - 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a SRS component is being serviced, the SRS must be depowered. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9744 - The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a SRS fault. - 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 smart junction box (SJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse 17 (10A) from the SJB. 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 front impact severity sensors are located on the radiator support bracket above the lower front splash shield. The front door side impact sensors are located in the first row doors, behind the door trim panel. The C-pillar side impact sensors (if equipped) are located on the C-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). Disconnect the battery ground cable and wait at least one minute. 7. Remove the 2 driver air bag module bolts (1 shown). 8. NOTE: Note the position of the 3 driver air bag module wiring connectors for installation. Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag module. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9745 9. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of the steering column. 10. Open and lower the glove compartment door. 11. Detach the wiring retainer, remove the 4 bolts and the passenger air bag module heat shield. 12. NOTE: Deactivate the passenger air bag module as shown, the canister vent and adaptive tether squibs do not require deactivation. Through the glove compartment opening, disconnect the LH side passenger air bag module electrical connector. 13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector on the LH side. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9746 14. From under the rear of the passenger seat, detach the passenger seat side air bag module electrical connector from the seat track bracket. Then slide and disengage the passenger seat side air bag module electrical connector locking clip, and then release the tab and disconnect the passenger seat side air bag module electrical connector. 15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat side air bag module electrical connector. Vehicles without safety canopy modules 16. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy bridge resistor from the safety canopy electrical connector. If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the RCM. If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low resistance fault will be generated by the RCM. Explorer and Mountaineer vehicles with safety canopy modules 17. Release and position aside the passenger side C-pillar trim panel. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9747 18. Disconnect the passenger side safety canopy module electrical connector. 19. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. 20. Release and position aside the driver side C-pillar trim panel. 21. Disconnect the driver side safety canopy module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9748 22. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. Explorer Sport Trac vehicles with safety canopy modules 23. Remove the driver and passenger side upper C-pillar trim panels. 24. Disconnect the passenger side safety canopy module electrical connector. 25. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. 26. Disconnect the driver side safety canopy module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9749 27. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. All vehicles 28. From under the rear of the driver seat, slide and disengage the driver seat side air bag module electrical connector locking clip, and then release the tab and disconnect the driver seat side air bag module electrical connector. 29. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air bag module electrical connector. 30. Install the RCM fuse 17 (10A) to the SJB. 31. Connect the battery ground cable. Reactivation All vehicles 1. Remove the RCM fuse 17 (10A) from the SJB. 2. Disconnect the battery ground cable and wait at least one minute. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9750 3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat side air bag module electrical connector. 4. Connect the driver seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Explorer Sport Trac vehicles with safety canopy modules 5. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 6. Connect the driver side safety canopy module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9751 7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 8. Connect the passenger side safety canopy module electrical connector. 9. Install the driver and passenger upper C-pillar trim panels. Explorer and Mountaineer vehicles with safety canopy modules 10. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 11. Connect the driver side safety canopy module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9752 12. Install the driver side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. 13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 14. Connect the passenger side safety canopy module electrical connector. 15. Install the passenger side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. All vehicles Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9753 16. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat side air bag module electrical connector. 17. Connect the passenger seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Then attach the passenger seat side air bag module electrical connector to the seat track bracket. 18. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector on the LH side. 19. Connect the LH side passenger air bag module electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9754 20. Install the passenger air bag module heat shield and the 4 bolts. Attach the wiring retainer. 21. Close glove compartment door. 22. Remove the restraint system diagnostic tools from the clockspring electrical connectors at the top of the steering column. 23. CAUTION: The clockspring electrical connectors are unique and cannot be connected to the driver air bag module in the wrong position. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Connect the driver air bag module electrical connectors as noted in removal. 24. Install the 2 driver air bag module bolts (1 shown). - Tighten to 7 Nm (62 lb-in). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 9755 25. 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. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 26. Turn the ignition switch from OFF to ON. 27. Install the RCM fuse 17 (10A) to the SJB and install the cover. 28. 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. 29. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the switch 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 6 seconds and then turn off. If an air bag SRS fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag indicator might not light 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 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 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and occupant classification sensor (OCS) module using a scan tool. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Service and Repair > Instrument Cluster Bulb Instrument Panel Bulb: Service and Repair Instrument Cluster Bulb INSTRUMENT CLUSTER BULB 1. Remove the instrument cluster. 2. NOTE: To remove the illumination bulb, rotate the bulb one quarter turn counterclockwise and lift out from the instrument cluster. Remove the illumination bulb(s). 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Service and Repair > Instrument Cluster Bulb > Page 9760 Instrument Panel Bulb: Service and Repair Warning Indicator Bulb WARNING INDICATOR BULB Removal and Installation 1. Remove the instrument cluster. 2. NOTE: To remove a warning indicator bulb, rotate the bulb one quarter turn counterclockwise and lift it out from the instrument cluster. Remove the warning indicator bulb(s) in question. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets Instrument Panel Control Module: Customer Interest Instruments - Trip Odometers/Fuel Economy Resets TSB 09-21-7 11/02/09 TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS UNINTENTIONALLY FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally. This condition may occur if there is an intermittent electrical connection on the power feed to the cluster or if the reset button on the 3-button message center assembly is momentarily touched. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. With the key in the On position, display the trip odometer mileage. 2. Start the vehicle. 3. Cycle the key back Off and restart the vehicle. 4. Verify whether the trip mileage reset or not. 5. If not, proceed to Step 10. 6. If it reset, turn the key Off and remove the key from the ignition. 7. Activate the emergency flashers. 8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal fuse and wiring diagnostics to correct the power feed circuit. 9. Verify repair and proceed to Step 10. 10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release 63.07 and higher. This new calibration is not included in the VCM 2009.9 DVD. Calibration files may also be obtained at the website. NOTE REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT RESOLVE THIS ISSUE. 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 092107A 2006-2010 Explorer, 0.3 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 9769 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets Instrument Panel Control Module: All Technical Service Bulletins Instruments - Trip Odometers/Fuel Economy Resets TSB 09-21-7 11/02/09 TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS UNINTENTIONALLY FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally. This condition may occur if there is an intermittent electrical connection on the power feed to the cluster or if the reset button on the 3-button message center assembly is momentarily touched. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. With the key in the On position, display the trip odometer mileage. 2. Start the vehicle. 3. Cycle the key back Off and restart the vehicle. 4. Verify whether the trip mileage reset or not. 5. If not, proceed to Step 10. 6. If it reset, turn the key Off and remove the key from the ignition. 7. Activate the emergency flashers. 8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal fuse and wiring diagnostics to correct the power feed circuit. 9. Verify repair and proceed to Step 10. 10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release 63.07 and higher. This new calibration is not included in the VCM 2009.9 DVD. Calibration files may also be obtained at the website. NOTE REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT RESOLVE THIS ISSUE. 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 092107A 2006-2010 Explorer, 0.3 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 9775 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Testing and Inspection Low Tire Pressure Indicator: Testing and Inspection TPMS Indicator and Message Center Messages The TPMS indicator and vehicle message center (if equipped) sometimes displays faults that cannot be resolved by the customer. Treat these messages as TPMS faults that must be serviced. TPMS Indicator Illuminates Continuously NOTE: If the spare tire is in use, the damaged road tire must be repaired and installed on the vehicle to restore complete TPMS functionality before carrying out any diagnosis. 1. The TPMS indicator remains on continuously for this condition: ^ Low Tire Pressure - The TPMS indicator is illuminated solid and the message center displays LOW TIRE PRESSURE (if equipped). This is displayed when any of the tire pressures are low. When this condition exists, the tire pressure must be adjusted to the recommended cold pressure as indicated on the vehicle certification label. 2. NOTE: The TPMS sensors do not transmit when the vehicle is stationary. If the vehicle has been stationary for more than 30 minutes, it will be necessary to wake up the sensors so they will transmit the latest tire pressure information to the SJB. If the vehicle has been stationary for more than 30 minutes, carry out this procedure to wake up the TPMS sensors. 1 Turn the ignition switch to the ON position. 2 Adjust the air pressure in the LF tire. 3 Activate the LF TPMS sensor, at least 2 times, using the tire pressure monitor activation tool. 4 Repeat Steps 2 and 3 for the remaining tires. 5 If the TPMS indicator remains illuminated after adjusting and activating each sensor, GO to Symptom Chart. See: Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures TPMS Indicator Flashes The TPMS indicator flashes for 70 seconds and then remains ON solid when the ignition key is turned to the ON position for these conditions: 1. Tire Pressure Sensor Fault - If equipped, the message center will display TIRE SENSOR FAULT when a tire pressure sensor is malfunctioning. GO to Symptom Chart. See: Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures 2. No communication with the SJB (TPMS is integral to the SJB) - The TPMS indicator is illuminated when the instrument cluster has received no signals from the SJB for more than 5 seconds. If equipped, the message center displays TIRE MONITOR FAULT. GO to Symptom Chart. See: Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures 3. Tire Pressure Monitor Fault - If equipped, the message center will display TIRE MONITOR FAULT when the tire pressure monitoring system is malfunctioning or communication with the instrument cluster has been lost. GO to Symptom Chart. See: Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair Maintenance Required Lamp/Indicator: Service and Repair To reset the oil monitoring system to 100% after each oil change [approximately 5,000 miles (8,000 km) or 180 days] perform the following: 1. Enter SYSTEM CHECK to display HOLD RESET IF NEW OIL. 2. Press and hold the RESET control switch for more than 2 seconds. Oil life is set to 100% and OIL LIFE SET TO 100% is displayed. Note: To change oil life 100% miles value from 5,000 miles (8,000 km) or 180 days to another value, refer to the Oil Life Start Value selected from the SETUP MENU. Oil Life Start Value 1. Select this function from the SETUP MENU for the current display mode. 2. Press and hold the TRIP/RESET control switch to reset oil change. 3. Press the TRIP/RESET control switch for the next SETUP MENU item or wait for more than 4 seconds to return to the INFO MENU. Note: Oil Life Start Value of 100% equals 5,000 miles (8,000 km) and 180 days. Setting Oil Life Start Value to 60% sets the Oil Lift Start Value to 3,000 miles (4,828 km) and 120 days. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) CHECK ENGINE, SERVICE ENGINE SOON, Or ISO Standard Engine Symbol The MIL notifies the driver that the powertrain control module (PCM) has detected an on board diagnostic (OBD) emission-related component or system concern. When this occurs, an OBD diagnostic trouble code (DTC) sets. - The MIL is located in the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE SOON or the international standards organization (ISO) standard engine symbol. - The MIL is illuminated during the instrument cluster prove out for approximately 4 seconds. - The MIL remains illuminated after instrument cluster prove out if: an emission-related concern and DTC exists. - the PCM does not send a control message to the instrument cluster (applications with the MIL controlled through the communication link). - the PCM is operating in the hardware limited operation strategy (HLOS). - The MIL remains off during the instrument cluster prove out if an indicator or instrument cluster concern is present. - To turn off the MIL after a repair, a reset command from the scan tool must be sent, or 3 consecutive drive cycles must be completed without a concern. - For all MIL concerns, go to Symptom Charts. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures - If the MIL flashes at a steady rate, a severe misfire condition may exist. - If the MIL flashes erratically, the PCM can reset while cranking if the battery voltage is low. - The MIL flashes after a period of time with the key in the RUN position (engine not running) if DTC P1000 is set. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Customer Interest for Odometer: > 10-2-15 > Feb > 10 > Instruments - Odometer Display Moves On Screen Odometer: Customer Interest Instruments - Odometer Display Moves On Screen TSB 10-2-15 02/15/10 ODOMETER DISPLAY READING MOMENTARILY FLIPS FROM BOTTOM TO TOP OF MESSAGE CENTER SCREEN FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit a condition where the odometer display reading momentarily flips from the bottom to the top of the message center screen, then back to the normal display mode (Figure 1). This concern may be very intermittent and difficult to verify. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE The following procedure involves installing a Fair Rite Round Cable Snap-On Suppressor (only one required) which must be ordered directly from the supplier Newark listed below: ^ Newark telephone number 1-800-463-9275. ^ Newark website: www.Newark.com. ^ Newark part number: 78K6137. ^ Manufacturer: Fair Rite. ^ Manufacturer part number: 0444176451. 1. Remove the Instrument Cluster (IC). Refer to the Workshop Manual (WSM), Section 413-01. NOTE IT IS NOT NECESSARY TO DOWNLOAD THE IC CONFIGURATION INFORMATION. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Customer Interest for Odometer: > 10-2-15 > Feb > 10 > Instruments - Odometer Display Moves On Screen > Page 9793 2. Install the Fair Rite Round Cable Snap-On Suppressor around the cluster harness circuits. (Figure 3) 3. Install PVC tape (164-R4901) from Rotunda kit (164-R4900) around the suppressor. (Figure 4) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Customer Interest for Odometer: > 10-2-15 > Feb > 10 > Instruments - Odometer Display Moves On Screen > Page 9794 4. Install a tie strap in between the Suppressor and the wiring harness. (Figure 5) 5. Tuck the suppressor behind the IC plastic support bracket and secure the tie strap around the instrument cluster bracket. (Figure 6) 6. Install the IC. Refer to WSM, Section 413-01. 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 100215A 2006-2010 Explorer, 0.7 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Install Suppressor, Includes Time To Remove And Install The Instrument Cluster (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 10849 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Customer Interest for Odometer: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets Odometer: Customer Interest Instruments - Trip Odometers/Fuel Economy Resets TSB 09-21-7 11/02/09 TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS UNINTENTIONALLY FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally. This condition may occur if there is an intermittent electrical connection on the power feed to the cluster or if the reset button on the 3-button message center assembly is momentarily touched. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. With the key in the On position, display the trip odometer mileage. 2. Start the vehicle. 3. Cycle the key back Off and restart the vehicle. 4. Verify whether the trip mileage reset or not. 5. If not, proceed to Step 10. 6. If it reset, turn the key Off and remove the key from the ignition. 7. Activate the emergency flashers. 8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal fuse and wiring diagnostics to correct the power feed circuit. 9. Verify repair and proceed to Step 10. 10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release 63.07 and higher. This new calibration is not included in the VCM 2009.9 DVD. Calibration files may also be obtained at the website. NOTE REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT RESOLVE THIS ISSUE. 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 092107A 2006-2010 Explorer, 0.3 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Customer Interest for Odometer: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 9799 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Odometer: > 10-2-15 > Feb > 10 > Instruments - Odometer Display Moves On Screen Odometer: All Technical Service Bulletins Instruments - Odometer Display Moves On Screen TSB 10-2-15 02/15/10 ODOMETER DISPLAY READING MOMENTARILY FLIPS FROM BOTTOM TO TOP OF MESSAGE CENTER SCREEN FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit a condition where the odometer display reading momentarily flips from the bottom to the top of the message center screen, then back to the normal display mode (Figure 1). This concern may be very intermittent and difficult to verify. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE The following procedure involves installing a Fair Rite Round Cable Snap-On Suppressor (only one required) which must be ordered directly from the supplier Newark listed below: ^ Newark telephone number 1-800-463-9275. ^ Newark website: www.Newark.com. ^ Newark part number: 78K6137. ^ Manufacturer: Fair Rite. ^ Manufacturer part number: 0444176451. 1. Remove the Instrument Cluster (IC). Refer to the Workshop Manual (WSM), Section 413-01. NOTE IT IS NOT NECESSARY TO DOWNLOAD THE IC CONFIGURATION INFORMATION. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Odometer: > 10-2-15 > Feb > 10 > Instruments - Odometer Display Moves On Screen > Page 9805 2. Install the Fair Rite Round Cable Snap-On Suppressor around the cluster harness circuits. (Figure 3) 3. Install PVC tape (164-R4901) from Rotunda kit (164-R4900) around the suppressor. (Figure 4) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Odometer: > 10-2-15 > Feb > 10 > Instruments - Odometer Display Moves On Screen > Page 9806 4. Install a tie strap in between the Suppressor and the wiring harness. (Figure 5) 5. Tuck the suppressor behind the IC plastic support bracket and secure the tie strap around the instrument cluster bracket. (Figure 6) 6. Install the IC. Refer to WSM, Section 413-01. 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 100215A 2006-2010 Explorer, 0.7 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Install Suppressor, Includes Time To Remove And Install The Instrument Cluster (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 10849 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Odometer: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets Odometer: All Technical Service Bulletins Instruments - Trip Odometers/Fuel Economy Resets TSB 09-21-7 11/02/09 TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS UNINTENTIONALLY FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally. This condition may occur if there is an intermittent electrical connection on the power feed to the cluster or if the reset button on the 3-button message center assembly is momentarily touched. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. With the key in the On position, display the trip odometer mileage. 2. Start the vehicle. 3. Cycle the key back Off and restart the vehicle. 4. Verify whether the trip mileage reset or not. 5. If not, proceed to Step 10. 6. If it reset, turn the key Off and remove the key from the ignition. 7. Activate the emergency flashers. 8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal fuse and wiring diagnostics to correct the power feed circuit. 9. Verify repair and proceed to Step 10. 10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release 63.07 and higher. This new calibration is not included in the VCM 2009.9 DVD. Calibration files may also be obtained at the website. NOTE REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT RESOLVE THIS ISSUE. 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 092107A 2006-2010 Explorer, 0.3 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Odometer: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 9811 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair Message Center Configuration Oil Life Reset - Message Center Cluster NOTE:The oil life calculation is set at a maximum of approximately 8,000 km (5,000 miles) or 180 days 1. Press and release the SETUP button until the message center displays PRESS RESET TO BEGIN SYSTEM CHECK. 2. Press and release the RESET button until the message center displays HOLD RESET IF NEW OIL. 3. Press and hold the RESET button for 2 seconds and release to reset the oil life to 100%. 4. The message center displays SETUP MENU HOLD RESET. Oil Life Reset - Base Instrument Cluster NOTE: The oil life calculation is set at a maximum of approximately 8,000 km (5,000 miles) or 180 days. 1. Place the ignition in the RUN position with the engine off (KOEO). 2. Press and release the TRIP/RESET button until SETUP MENU HOLD RESET is displayed. 3. Press and hold the TRIP/RESET button until SYSTEM CHECK is displayed. 4. Release the TRIP/RESET button. 5. Press and release the TRIP/RESET button to scroll through the system check menu items until HOLD RESET IF NEW OIL is displayed. 6. Press and hold the TRIP/RESET button until OIL LIFE SET TO 100% is displayed. 7. Release the TRIP/RESET button. The oil life is now reset. Oil Life Start Value - Message Center Cluster NOTE:The oil life start value is used to reset the oil life value back to the maximum of approximately 8,000 km (5,000 miles) if the value was previously changed or to lower the value from the maximum (8,000 km To reset the oil monitoring system to 100% after each oil change [approximately 5,000 miles (8,000 km) or 180 days] perform the following: 1. Enter SYSTEM CHECK to display "OIL XXX% OIL LIFE OK". 2. Press RESET control to display "HOLD RESET IF NEW OIL". 3. Press and hold RESET control for more than 2 seconds. Oil life is set to 100% and "OIL CHANGE SET TO 100%" is displayed. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations View 151-1 (Engine Compartment - 4.0L, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 9818 C103 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator > Component Information > Diagrams C4015 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations View 151-13 (Left Front) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 9825 C2015 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > Customer Interest for Fuel Distance/Mileage Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets Fuel Distance/Mileage Module: Customer Interest Instruments - Trip Odometers/Fuel Economy Resets TSB 09-21-7 11/02/09 TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS UNINTENTIONALLY FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally. This condition may occur if there is an intermittent electrical connection on the power feed to the cluster or if the reset button on the 3-button message center assembly is momentarily touched. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. With the key in the On position, display the trip odometer mileage. 2. Start the vehicle. 3. Cycle the key back Off and restart the vehicle. 4. Verify whether the trip mileage reset or not. 5. If not, proceed to Step 10. 6. If it reset, turn the key Off and remove the key from the ignition. 7. Activate the emergency flashers. 8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal fuse and wiring diagnostics to correct the power feed circuit. 9. Verify repair and proceed to Step 10. 10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release 63.07 and higher. This new calibration is not included in the VCM 2009.9 DVD. Calibration files may also be obtained at the website. NOTE REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT RESOLVE THIS ISSUE. 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 092107A 2006-2010 Explorer, 0.3 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > Customer Interest for Fuel Distance/Mileage Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 9835 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Distance/Mileage Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets Fuel Distance/Mileage Module: All Technical Service Bulletins Instruments - Trip Odometers/Fuel Economy Resets TSB 09-21-7 11/02/09 TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS UNINTENTIONALLY FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally. This condition may occur if there is an intermittent electrical connection on the power feed to the cluster or if the reset button on the 3-button message center assembly is momentarily touched. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. With the key in the On position, display the trip odometer mileage. 2. Start the vehicle. 3. Cycle the key back Off and restart the vehicle. 4. Verify whether the trip mileage reset or not. 5. If not, proceed to Step 10. 6. If it reset, turn the key Off and remove the key from the ignition. 7. Activate the emergency flashers. 8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal fuse and wiring diagnostics to correct the power feed circuit. 9. Verify repair and proceed to Step 10. 10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release 63.07 and higher. This new calibration is not included in the VCM 2009.9 DVD. Calibration files may also be obtained at the website. NOTE REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT RESOLVE THIS ISSUE. 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 092107A 2006-2010 Explorer, 0.3 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Distance/Mileage Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 9841 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets Instrument Panel Control Module: Customer Interest Instruments - Trip Odometers/Fuel Economy Resets TSB 09-21-7 11/02/09 TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS UNINTENTIONALLY FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally. This condition may occur if there is an intermittent electrical connection on the power feed to the cluster or if the reset button on the 3-button message center assembly is momentarily touched. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. With the key in the On position, display the trip odometer mileage. 2. Start the vehicle. 3. Cycle the key back Off and restart the vehicle. 4. Verify whether the trip mileage reset or not. 5. If not, proceed to Step 10. 6. If it reset, turn the key Off and remove the key from the ignition. 7. Activate the emergency flashers. 8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal fuse and wiring diagnostics to correct the power feed circuit. 9. Verify repair and proceed to Step 10. 10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release 63.07 and higher. This new calibration is not included in the VCM 2009.9 DVD. Calibration files may also be obtained at the website. NOTE REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT RESOLVE THIS ISSUE. 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 092107A 2006-2010 Explorer, 0.3 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 9850 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets Instrument Panel Control Module: All Technical Service Bulletins Instruments - Trip Odometers/Fuel Economy Resets TSB 09-21-7 11/02/09 TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS UNINTENTIONALLY FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac MERCURY: 2006-2010 Mountaineer ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally. This condition may occur if there is an intermittent electrical connection on the power feed to the cluster or if the reset button on the 3-button message center assembly is momentarily touched. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. With the key in the On position, display the trip odometer mileage. 2. Start the vehicle. 3. Cycle the key back Off and restart the vehicle. 4. Verify whether the trip mileage reset or not. 5. If not, proceed to Step 10. 6. If it reset, turn the key Off and remove the key from the ignition. 7. Activate the emergency flashers. 8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal fuse and wiring diagnostics to correct the power feed circuit. 9. Verify repair and proceed to Step 10. 10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release 63.07 and higher. This new calibration is not included in the VCM 2009.9 DVD. Calibration files may also be obtained at the website. NOTE REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT RESOLVE THIS ISSUE. 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 092107A 2006-2010 Explorer, 0.3 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 9856 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation Safety Belt Warning Indicator And Chime The warning indicator and chime are reminders to fasten the safety belt. The system operates as follows: If the driver safety belt is not buckled before the ignition switch is turned to the RUN or START position, the indicator will illuminate for 1-2 minutes and the chime will sound for 4-8 seconds. - If the driver safety belt is buckled while the indicator is on and the chime is sounding, both the indicator and chime will turn off. - If the safety belt is buckled before the ignition is turned to the ON position, neither the indicator nor the chime will turn on. Belt Minder The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature provides an additional reminder that the driver's and/or front passenger's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning lamp in the instrument cluster. To activate or deactivate the Belt Minder feature, refer to Seat Belt Systems or the owner's literature. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Testing and Inspection > Page 9864 Dimmer Switch: Service and Repair INSTRUMENT PANEL DIMMER SWITCH Removal and Installation 1. Remove the driver side register. 2. Remove the headlamp switch and bezel as an assembly. - Disconnect the electrical connectors. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Testing and Inspection > Page 9865 3. Release the 2 tabs and remove the instrument panel dimmer switch. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front View 151-21 (Driver Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 9870 View 151-22 (Passenger Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 9871 View 151-24 (Left Rear Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 9872 View 151-23 (Right Rear Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 9873 Door Switch: Locations View 151-21 (Driver Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 9874 View 151-22 (Passenger Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 9875 View 151-24 (Left Rear Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 9876 View 151-23 (Right Rear Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 9877 View 151-25 (Liftgate) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 9878 View 151-25 (Liftgate) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch C479 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 9881 C478 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 9882 C526 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 9883 C602 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 9884 Door Switch: Diagrams C479 C478 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 9885 C526 C602 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 9886 C715 C820 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 Fuel Gauge Sender: Customer Interest Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 TSB 06-17-10 09/04/06 MIL ON WITH DTC P0463 OR ERRATIC FUEL GAUGE OPERATION FORD: 2004-2007 Explorer MERCURY: 2004-2007 Mountaineer This article supersedes TSB 06-16-7 to update the Service Procedure. ISSUE Some 2004-2007 Explorer 4dr/Mountaineer vehicles may exhibit the malfunction indicator lamp (MIL) on with diagnostic trouble code (DTC) P0463 or an erratic fuel gauge concern. This could be from sulphur contamination in the fuel, causing an open or high resistance on the fuel sender card. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. For vehicles with customer symptom of erratic fuel gauge operation (with no MIL on), proceed to Step 1a. For vehicles with a customer symptom including the MIL on, proceed to Step 1b. If unable to verify the concern, do not continue with this TSB. a. Follow the appropriate pinpoint test (PPT) for "Fuel Gauge Inaccurate" in Workshop Manual (WSM), Section 413-01. If PPT test results lead to fuel pump module replacement, proceed to Step 2. If PPT test results isolate any problem other than fuel pump module replacement, repair as indicated and do not continue with this TSB. b. Install diagnostic scan tool to retrieve DTCs. If DTC P0463 is retrieved, proceed to Step 2. If DTC P0463 is not retrieved, this TSB does not apply, follow normal WSM diagnostics. 2. Remove fuel tank per WSM, Section 310-01. 3. Remove fuel pump assembly from fuel tank per WSM, Section 310-01. See Figure 1 (Chart) to determine if a kit (contains a fuel level sensor assembly, a wire harness and heat shrink tube) or fuel pump assembly is required for repair. For vehicles that can be serviced with a kit go to Step 4. For vehicles that require fuel pump assembly replacement, go to Step 12. 4. Remove the fuel level sensor assembly (sender card/float rod assembly) from the fuel pump assembly per WSM, Section 310-01. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 9895 5. Detach electrical connector from fuel pump housing (Figure 2). 6. Remove wiring harness from the fuel pump assembly flange by depressing the retaining fingers on the harness connector at bottom of flange and pushing upward out of flange (Figure 3). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 9896 7. Install new wiring harness by feeding wires through flange hole and inserting harness connector into flange until an audible click is heard. Check for proper retention. 8. Re-attach electrical connector harness to fuel pump housing. Prior to making the connection place one loop in the pump wires away from the convoluted feed tube (Figure 4). 9. Re-attach the signal wire (yellow) on the harness to the signal wire (yellow) on the replacement fuel level sensor assembly per WSM, Section 310-01 (Figure 5). 10. Wrap the ground wire one time around the signal wire and attach the ground wire terminal to the terminal on the fuel level sensor assembly. Check for proper retention. NOTE THE GROUND WIRE MUST BE WRAPPED AROUND THE SIGNAL WIRE, AS DESCRIBED IN STEP 10, TO PREVENT POTENTIAL INTERFERENCE WITH THE FLOAT ROD ARM. 11. Re-attach the fuel level sensor assembly to the fuel pump housing, making sure that both the signal wire and the ground wire are routed through the Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 9897 gap between the fuel level sensor assembly and fuel pump bracket. Torque the fastener at the bottom of the fuel level sensor assembly to 1 N.m (9 lb-in). 12. Re-install fuel pump assembly into fuel tank per WSM, Section 310-01. NOTE TAKE CARE NOT TO DAMAGE/BEND FLOAT ROD OR SENDER CARD DURING INSTALLATION OF FUEL PUMP ASSEMBLY. 13. Re-install fuel tank per WSM, Section 310-01. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 061710A 2004-2007 2.9 Hrs. Explorer/Mountaineer: Diagnose And Replace The Fuel Gauge Tank Unit (Do Not Use With 9275D, 9275A, 9002A) DEALER CODING CONDITION BASIC PART NO. CODE 9A299 28 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 Fuel Gauge Sender: All Technical Service Bulletins Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 TSB 06-17-10 09/04/06 MIL ON WITH DTC P0463 OR ERRATIC FUEL GAUGE OPERATION FORD: 2004-2007 Explorer MERCURY: 2004-2007 Mountaineer This article supersedes TSB 06-16-7 to update the Service Procedure. ISSUE Some 2004-2007 Explorer 4dr/Mountaineer vehicles may exhibit the malfunction indicator lamp (MIL) on with diagnostic trouble code (DTC) P0463 or an erratic fuel gauge concern. This could be from sulphur contamination in the fuel, causing an open or high resistance on the fuel sender card. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. For vehicles with customer symptom of erratic fuel gauge operation (with no MIL on), proceed to Step 1a. For vehicles with a customer symptom including the MIL on, proceed to Step 1b. If unable to verify the concern, do not continue with this TSB. a. Follow the appropriate pinpoint test (PPT) for "Fuel Gauge Inaccurate" in Workshop Manual (WSM), Section 413-01. If PPT test results lead to fuel pump module replacement, proceed to Step 2. If PPT test results isolate any problem other than fuel pump module replacement, repair as indicated and do not continue with this TSB. b. Install diagnostic scan tool to retrieve DTCs. If DTC P0463 is retrieved, proceed to Step 2. If DTC P0463 is not retrieved, this TSB does not apply, follow normal WSM diagnostics. 2. Remove fuel tank per WSM, Section 310-01. 3. Remove fuel pump assembly from fuel tank per WSM, Section 310-01. See Figure 1 (Chart) to determine if a kit (contains a fuel level sensor assembly, a wire harness and heat shrink tube) or fuel pump assembly is required for repair. For vehicles that can be serviced with a kit go to Step 4. For vehicles that require fuel pump assembly replacement, go to Step 12. 4. Remove the fuel level sensor assembly (sender card/float rod assembly) from the fuel pump assembly per WSM, Section 310-01. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 9903 5. Detach electrical connector from fuel pump housing (Figure 2). 6. Remove wiring harness from the fuel pump assembly flange by depressing the retaining fingers on the harness connector at bottom of flange and pushing upward out of flange (Figure 3). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 9904 7. Install new wiring harness by feeding wires through flange hole and inserting harness connector into flange until an audible click is heard. Check for proper retention. 8. Re-attach electrical connector harness to fuel pump housing. Prior to making the connection place one loop in the pump wires away from the convoluted feed tube (Figure 4). 9. Re-attach the signal wire (yellow) on the harness to the signal wire (yellow) on the replacement fuel level sensor assembly per WSM, Section 310-01 (Figure 5). 10. Wrap the ground wire one time around the signal wire and attach the ground wire terminal to the terminal on the fuel level sensor assembly. Check for proper retention. NOTE THE GROUND WIRE MUST BE WRAPPED AROUND THE SIGNAL WIRE, AS DESCRIBED IN STEP 10, TO PREVENT POTENTIAL INTERFERENCE WITH THE FLOAT ROD ARM. 11. Re-attach the fuel level sensor assembly to the fuel pump housing, making sure that both the signal wire and the ground wire are routed through the Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 06-17-10 > Sep > 06 > Fuel System - Erratic Fuel Gauge/MIL ON/DTC P0463 > Page 9905 gap between the fuel level sensor assembly and fuel pump bracket. Torque the fastener at the bottom of the fuel level sensor assembly to 1 N.m (9 lb-in). 12. Re-install fuel pump assembly into fuel tank per WSM, Section 310-01. NOTE TAKE CARE NOT TO DAMAGE/BEND FLOAT ROD OR SENDER CARD DURING INSTALLATION OF FUEL PUMP ASSEMBLY. 13. Re-install fuel tank per WSM, Section 310-01. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 061710A 2004-2007 2.9 Hrs. Explorer/Mountaineer: Diagnose And Replace The Fuel Gauge Tank Unit (Do Not Use With 9275D, 9275A, 9002A) DEALER CODING CONDITION BASIC PART NO. CODE 9A299 28 Disclaimer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 9906 Fuel Gauge Sender: Description and Operation FUEL PUMP (FP) MODULE Typical Electronic Returnless Fuel Pump (FP) Module Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 9907 Typical Mechanical Returnless Fuel Pump (FP) Module The FP module 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. FUEL PUMP (FP) MODULE AND RESERVOIR The FP module is mounted inside the fuel tank in a reservoir. The pump has a discharge check valve that maintains the system pressure after the key has been turned off to minimize starting concerns. The reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low tank fill levels. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 9908 Fuel Gauge Sender: Service and Repair FUEL LEVEL SENSOR Explorer Sport Trac (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 9909 Explorer Sport Trac (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 9910 Explorer/Mountaineer (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 9911 Explorer/Mountaineer (Part 2) All Vehicles (Part 1) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 9912 All Vehicles (Part 2) Removal 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. 1. Remove the fuel pump. 2. NOTE: Note the routing of the sending unit wire for installation. Remove the heat shrink tube covering the electrical connector. 3. Disconnect the electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 9913 4. Remove the screw and lift up to remove the fuel gauge sending unit. Installation 1. Route the fuel gauge sending unit wire through the center of the fuel pump module. 2. NOTE: - Both fuel gauge sending wires must be routed behind the metal sending unit plate. - The grounding eyelet must be on the front side of the sending unit. Hook the fuel gauge sending unit on the fuel pump module and install the screw through the grounding eyelet and tighten the screw. 3. Slide the heat shrink tube onto the wire harness and connect the electrical connector. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 9914 4. WARNING: Do not use an open flame to shrink the heat shrink tube, use a heat gun only. Failure to follow these instructions may result in personal injury. Using a heat gun, shrink the heat shrink tube. 5. Install the fuel pump. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations View 151-13 (Left Front) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 9918 C2015 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Testing and Inspection Low Tire Pressure Indicator: Testing and Inspection TPMS Indicator and Message Center Messages The TPMS indicator and vehicle message center (if equipped) sometimes displays faults that cannot be resolved by the customer. Treat these messages as TPMS faults that must be serviced. TPMS Indicator Illuminates Continuously NOTE: If the spare tire is in use, the damaged road tire must be repaired and installed on the vehicle to restore complete TPMS functionality before carrying out any diagnosis. 1. The TPMS indicator remains on continuously for this condition: ^ Low Tire Pressure - The TPMS indicator is illuminated solid and the message center displays LOW TIRE PRESSURE (if equipped). This is displayed when any of the tire pressures are low. When this condition exists, the tire pressure must be adjusted to the recommended cold pressure as indicated on the vehicle certification label. 2. NOTE: The TPMS sensors do not transmit when the vehicle is stationary. If the vehicle has been stationary for more than 30 minutes, it will be necessary to wake up the sensors so they will transmit the latest tire pressure information to the SJB. If the vehicle has been stationary for more than 30 minutes, carry out this procedure to wake up the TPMS sensors. 1 Turn the ignition switch to the ON position. 2 Adjust the air pressure in the LF tire. 3 Activate the LF TPMS sensor, at least 2 times, using the tire pressure monitor activation tool. 4 Repeat Steps 2 and 3 for the remaining tires. 5 If the TPMS indicator remains illuminated after adjusting and activating each sensor, GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures TPMS Indicator Flashes The TPMS indicator flashes for 70 seconds and then remains ON solid when the ignition key is turned to the ON position for these conditions: 1. Tire Pressure Sensor Fault - If equipped, the message center will display TIRE SENSOR FAULT when a tire pressure sensor is malfunctioning. GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures 2. No communication with the SJB (TPMS is integral to the SJB) - The TPMS indicator is illuminated when the instrument cluster has received no signals from the SJB for more than 5 seconds. If equipped, the message center displays TIRE MONITOR FAULT. GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures 3. Tire Pressure Monitor Fault - If equipped, the message center will display TIRE MONITOR FAULT when the tire pressure monitoring system is malfunctioning or communication with the instrument cluster has been lost. GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Special Tool(s) NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure information to the Smart Junction Box (SJB). NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire Pressure Monitoring System (TPMS). Radio frequency noise is generated by electrical motors and appliance operation, cellular telephones, remote transmitters, power inverters and portable entertainment equipment. NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor again. NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire procedure must be repeated. NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for front and rear tires, tire rotation will not affect the system. 1. Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3. Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. - The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center will display TRAIN LF TIRE. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire Pressure Monitor Activation Tool must remain in place 180 degrees from the valve stem. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 9926 6. Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press and release the test button on the Tire Pressure Monitor Activation Tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB. 7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF tire sidewall opposite (180 degrees) from the valve stem and press and release the test button to train the RF tire pressure sensor. NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and the entire procedure must be repeated. 8. Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not successful. 9. Using the scan tool, locate the updated TPMS sensor identifiers trained to the SJB and document them on the applicable warranty claim. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode and to make sure there are no other concerns with a newly programmed SJB. 10. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and carry out the SJB On-Demand Self Test. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Tire Pressure Monitoring System (TPMS) Sensor Disassembly CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor can be removed and installed without removing the strap or the cradle. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. 1. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. 2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip can occur. Using a pocket screwdriver, or similar tool, remove the sensor locking clip. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 9929 3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor can occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. 4. Remove the sensor. Assembly 1. CAUTION: Damage to the sensor can occur if excessive force is applied during sensor installation. NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise when correctly seated. Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the sensor locking clip cannot be fully inserted, then the sensor may not be fully seated on the cradle or the locking clip may be inserted backward. Insert a new locking clip into the sensor. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 9930 3. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Training. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 9931 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Material Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 9932 Disassembly CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable. NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There are several different strap kits available based on wheel diameter but all strap kits share the same base part number. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. 1. Remove the tire pressure monitoring system (TPMS) sensor. 2. WARNING: The TPMS band is under tension. Always use safety goggles or a face shield and gloves when removing the TPMS band/strap. Failure to follow these instructions may result in personal injury. Remove a factory installed strap in this sequence: 1 Locate the strap buckle and secure the strap to the wheel using duct tape or a similar item, on both sides of the buckle approximately 25 mm (0.98 inch) from the buckle. 2 Using a large screwdriver and a twisting motion, unbuckle the strap. 3 Discard the strap. To remove a dealer installed strap, turn the worm gear screw until the strap is fully released from the worm gear. ^ Discard the strap. 3. NOTE: To aid assembly, mark the location of the cradle prior to disassembly. Using a screwdriver, or similar tool, remove the cradle by inserting the screwdriver under the cradle and prying up. Assembly 1. NOTE: Make sure the sensor is fully seated into the new cradle. The sensor will make a "click" noise when fully seated. Position the sensor into the new cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor down onto the cradle. 2. CAUTION: Metal scrapers can damage the wheel. Use only plastic or non-metallic scrapers to remove the cradle adhesive strip residue. NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the valve stem. Clean the area where the sensor and cradle are to be installed. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 9933 3. NOTE: The sensor and cradle must be positioned with the hinge side of the sensor on the RH side when viewed from the curb side (beauty side) of the wheel. NOTE: The sensor has raised markings indicating how to position the sensor. Remove the adhesive tape liner from the cradle and position the sensor and cradle into the wheel drop well 180° from the valve stem. 4. Install the tapered end of the strap through the opening of the cradle on the hinge side of the sensor. This will position the worm gear on the locking clip side of the sensor. 5. CAUTION: Steel wheels have a "high spot" along their circumference. Make sure the strap is positioned in the lowest spot possible for correct sensor and cradle retention. NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear. Position the worm gear 13 - 26 mm (0.5 - 1.0 inch) away from the sensor and tighten the worm gear. ^ Tighten to 3 Nm (27 inch lbs.) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 9934 6. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. 7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor training procedure. Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Training. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 (TCIL) The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations View 151-11 (behind Dash Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 9942 C286 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 9943 Ambient Light Sensor: Service and Repair LIGHT SENSOR Removal and Installation 1. Position the top portion of the lower center instrument panel finish panel rearward. 2. Remove the upper center instrument panel finish panel. - Disconnect the electrical connector. 3. Remove the 2 screws and the light sensor. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 9948 C167 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 9949 Backup Lamp Switch: Testing and Inspection Digital Transmission Range (TR) Sensor Diagnosis Chart Digital Transmission Range (TR) Sensor Diagnosis Chart Wiggle Test Information for Open/Shorts ^ TR4, TR3A, TR2 and TR1 are all closed in PARK. PARK is a good position to check for intermittent open circuits (with scan tool monitoring TRD). ^ TR4, TR3A, TR2 and TR1 are all open in OVERDRIVE, so OVERDRIVE is a good position to check for shorts to ground. To determine the shorted components while observing TRD, unplug the TR and determine if the short goes away. If the short is still present unplug the transmission harness and determine if the short goes away. If the short is still present, then the short is in the PCM or vehicle harness. Remove the suspect circuit(s) wire terminal from the PCM connector. If the short is still present, then the PCM has an internal failure, otherwise the failure is in the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions Brake Lamp: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9954 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9955 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9956 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9957 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9958 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9959 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9960 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9961 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9962 Brake Lamp: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9963 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9964 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9965 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9966 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9967 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9968 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9969 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9970 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9971 Brake Lamp: Connector Views C419 C418 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9972 C4032 C4035 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9973 Brake Lamp: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 90-1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9974 90-4 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. See: Diagrams/Components/Component Location Views Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 INSPECTION AND VERIFICATION 1. Verify the customer concern. Visual Inspection Chart 2. Visually inspect for obvious signs of mechanical or electrical damage. 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. NOTE: - Make sure the headlamp switch is in the OFF position. - Make sure the multifunction switch is in the LOW BEAM position. 4. NOTE: Make sure to use the latest scan tool release software. If the cause is not visually evident, connect the scan tool to the data link connector (DLC). 5. NOTE: The vehicle communication module (VCM) LED prove-out confirms power and ground from the DLC are provided to the VCM. If the scan tool does not communicate with the VCM: Check the VCM connection to the vehicle. - Check the scan tool connection to the VCM. - Refer to Information Bus (Module Communications Network), No Power To The Scan Tool, to diagnose no communication with the scan tool. 6. If the scan tool does not communicate with the vehicle: - Verify the ignition key is in the ON position. - Verify the scan tool operation with a known good vehicle. - Refer to Information Bus (Module Communications Network) to diagnose no response from the powertrain control module (PCM). 7. Carry out the network test. - If the scan tool responds with no communication with the SJB, refer to Information Bus (Module Communications Network). - If the network test passes, retrieve and record the continuous memory DTCs. 8. Clear the continuous DTCs and carry out the self-test diagnostics for the SJB. 9. If the DTCs retrieved are related to the concern, go to the Smart Junction Box (SJB) Diagnostic Trouble Code (DTC) Chart. For all other DTCs, refer to Information Bus (Module Communications Network). See: Diagnostic Trouble Code Descriptions 10. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9977 B2048-B2051 / C1446-C1788 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9978 Symptom Chart Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9979 Brake Lamp: Pinpoint Tests Test H: The Stoplamps Are Inoperative PINPOINT TEST H: THE STOPLAMPS ARE INOPERATIVE H1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9980 H1-H3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9981 H4-H5 Normal Operation The stoplamp switch is supplied voltage through circuit SBP22 (BN/RD) from the smart junction box (SJB). When the brake pedal is applied, the stoplamp switch routes voltage to the SJB through circuit CCB08 (VT/WH). Possible Causes - Fuse - Circuit CCB08 (VT/WH) open - Circuit SBP22 (BN/RD) open - Stoplamp switch - SJB Test I: One or More Stoplamps Are Inoperative PINPOINT TEST I: ONE OR MORE STOPLAMPS ARE INOPERATIVE Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9982 I1-I2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9983 I2-I3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9984 I3-I4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9985 I5-I7 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9986 I8-I9 Normal Operation - All Vehicles When the brake pedal is applied, the stoplamp switch routes voltage to the smart junction box (SJB). The voltage is then routed out of the SJB to the high mounted stoplamp through circuit CCB08 (VT/WH). Normal Operation - Explorer When the SJB detects the brake pedal applied, the SJB provides voltage to the LH and RH rear stoplamps through circuits CLS18 (GY/BN) and CLS19 (VT/OG), respectively. Ground for the high mounted stoplamp and the LH rear stoplamp is provided through circuit GD149 (BK/GY). Ground for the RH rear stoplamp is provided through circuit GD151 (BK/GN). Normal Operation - Explorer Sport Trac When the SJB detects the brake pedal applied, the SJB provides voltage to the LH and RH rear stoplamps through circuits CLS18 (GY/BN) and CLS19 (VT/OG), respectively. Ground for the high mounted stoplamp is provided through circuit GD133 (BK). Ground for the LH and RH rear stoplamps is provided through circuit GD148 (BK/YE). Normal Operation - Mountaineer When the SJB detects the brake pedal applied, the SJB provides voltage to the LH and RH rear stoplamps through circuit CLS44 (VT/BN). Ground for the high mounted stoplamp and the LH rear stoplamp is provided through circuit GD149 (BK/GY). Ground for the RH rear stoplamp is provided through circuit GD151 (BK/GN). DTC B2048 - is a continuous and on-demand DTC that sets when the SJB detects a short to ground from the LH rear turn lamp voltage supply circuit. The self-test must be run after the repair in order for the SJB to enable the output for the LH rear turn lamp voltage supply. DTC B2049 - is a continuous and on-demand DTC that sets when the SJB detects an open or short to voltage from the LH rear turn lamp voltage supply circuit. DTC B2050 - is a continuous and on-demand DTC that sets when the SJB detects a short to ground from the RH rear turn lamp voltage supply circuit. The self-test must be run after the repair in order for the SJB to enable the output for the RH rear turn lamp voltage supply. DTC B2051 - is a continuous and on-demand DTC that sets when the SJB detects an open or short to voltage from the RH rear turn lamp voltage supply circuit. DTC C1788 - is a continuous and on-demand DTC that sets when the SJB detects a short to ground from the rear stoplamp voltage supply circuit. The self-test must be run after the repair in order for the SJB to enable the output for the rear stoplamp voltage supply. Possible Causes - Fuse - Circuit CCB08 (VT/WH) open - Circuit CLS18 (GY/BN) open or short to ground - Circuit CLS19 (VT/OG) open or short to ground - Circuit CLS44 (VT/BN) open or short to ground - Circuit GD133 (BK) open - Circuit GD148 (BK/YE) open - Circuit GD149 (BK/GY) open - Circuit GD151 (BK/GN) open - High mounted stoplamp - Light emitting diode (LED) module Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9987 - SJB. Test J: The Stoplamps Are On Continuously PINPOINT TEST J: THE STOPLAMPS ARE ON CONTINUOUSLY J1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9988 J2-J9 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9989 J10-J14 Normal Operation - All Vehicles When the brake pedal is applied, the stoplamp switch routes voltage to the smart junction box (SJB), the brake shift interlock actuator, the trailer electric brake controller, the four wheel drive (4WD) control module, the anti-lock brake system (ABS) module, and the powertrain control module (PCM) through circuit CCB08 (VT/WH). The voltage is then routed out of the SJB to the high mounted stoplamp through circuit CCB08 (VT/WH). Normal Operation - Explorer, Explorer Sport Trac When the SJB detects the brake pedal applied, the SJB provides voltage to the LH and RH rear stoplamps through circuits CLS18 (GY/BN) and CLS19 (VT/OG), respectively. Normal Operation - Mountaineer When the SJB detects the brake pedal applied, the SJB provides voltage to the LH and RH rear stoplamps through circuit CLS44 (VT/BN). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9990 DTC B1446 - is an on-demand DTC that sets when the SJB detects a short to voltage from the brake pedal applied input circuit. Possible Causes - Circuit CCB08 (VT/WH) short to voltage - Circuit CLS18 (GY/BN) short to voltage - Circuit CLS19 (VT/OG) short to voltage - Circuit CLS44 (VT/BN) short to voltage - Stoplamp switch - Brake shift interlock actuator - Trailer electric brake controller - SJB - 4WD control module - ABS module - PCM Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Page 9991 Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations View 151-1 (Engine Compartment - 4.0L, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 9995 C278 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 9996 Brake Light Switch: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 9997 Brake Light Switch: Service and Repair STOPLAMP SWITCH Removal and Installation CAUTION: Do not remove or repair the brake pedal, brake booster or master cylinder without first removing the stoplamp switch. Do not install the stoplamp switch without the brake pedal arm secured to the brake booster push rod. Do not pull or push on the brake pedal when removing or installing the stoplamp switch, as misadjustment or damage to the switch may occur. 1. Disconnect the stoplamp switch electrical connector. 2. Rotate the stoplamp switch 45 degrees clockwise and remove the stoplamp switch. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams C926 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams C475 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door Console Lamp Switch: Service and Repair Door Ajar Switch - Front Door DOOR AJAR SWITCH - FRONT DOOR Removal and Installation 1. Remove the front door latch. 2. Disconnect the front door ajar switch electrical connector. 3. Release the locking tab and rotate the front door ajar switch counterclockwise and remove the switch from the front door latch. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 10009 Console Lamp Switch: Service and Repair Door Ajar Switch - Rear Door DOOR AJAR SWITCH - REAR DOOR Removal and Installation 1. Remove the rear door latch. 2. Release the locking tab, rotate the rear door ajar switch counterclockwise and remove the switch from the rear door latch. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 10010 Console Lamp Switch: Service and Repair Door Ajar Switch - Liftgate DOOR AJAR SWITCH - LIFTGATE Removal and Installation 1. Remove the liftgate latch. 2. Release the locking tab, rotate the liftgate ajar switch counterclockwise and remove the ajar switch form the liftgate latch. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 10011 Console Lamp Switch: Service and Repair Door Ajar Switch - Liftgate Glass DOOR AJAR SWITCH - LIFTGATE GLASS Removal and Installation 1. Remove the liftgate window latch. 2. Rotate the liftgate window ajar switch counterclockwise and remove the ajar switch from the liftgate window latch. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams C254 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions Daytime Running Lamp: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10019 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10020 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10021 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10022 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10023 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10024 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10025 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10026 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10027 Daytime Running Lamp: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10028 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10029 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10030 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10031 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10032 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10033 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10034 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10035 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10036 Daytime Running Lamp: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 97-1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10037 97-2 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. See: Diagrams/Components/Component Location Views Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Page 10038 Daytime Running Lamp: Description and Operation DAYTIME RUNNING LAMPS (DRL) NOTE: The smart junction box (SJB) must be configured when installing a new module. The DRL system operates the low beam headlamps at a reduced intensity. The SJB supplies pulse width modulated (PWM) voltage to illuminate the low beam headlamps at a reduced intensity when the following conditions are met: - The headlamp switch is not in the HEADLAMPS ON position. - The ignition switch is in the RUN position. - The transmission is not in PARK (P). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection > Inspection and Verification Daytime Running Lamp: Testing and Inspection Inspection and Verification INSPECTION AND VERIFICATION NOTE: When installing a new smart junction box (SJB), it must be configured for this feature, if originally equipped. Refer to Information Bus (Module Communications Network). 1. Verify the customer concern by operating the daytime running lamps (DRL) following these steps: - Place the ignition switch in the RUN position. - Place the headlamp switch in the OFF position. - Place the transmission in any gear other than PARK (P). - If the DRL does not operate, make sure the SJB is configured for DRL before proceeding to the next step. 2. Verify the low beam operation. - Place the headlamp switch in the HEADLAMPS ON position. If the low beams do not operate correctly, refer to Headlamps for correct diagnosis. - If the low beams operate correctly and the DRL operation is incorrect, proceed to the next step. 3. Check the SJB inputs. - Monitor the ignition switch PIDs and the transmission gear status PIDs. If the ignition switch PIDs do not agree with the ignition switch position, refer to Ignition Switch to continue diagnosis of the ignition switch. - If the transmission gear status PIDs do not agree with the gear selector lever position, refer to Transmission Control Systems. or Transmission Control Systems to continue diagnosis of the transmission. - If the PIDs indicate correct ignition and transmission gear status, install a new SJB. Refer to Body Control Systems (Multifunction Electronic Control Module). Test the system for normal operation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection > Inspection and Verification > Page 10041 Daytime Running Lamp: Testing and Inspection Principles of Operation PRINCIPLES OF OPERATION NOTE: When installing a new smart junction box (SJB), it must be configured for this feature, if originally equipped. Refer to Information Bus (Module Communications Network). The SJB controls the DRL by using various inputs to determine whether or not the DRL should be illuminated. These inputs include: - Ignition switch position - Headlamp switch position - Headlamps on or off - Transmission gear selection Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection > Page 10042 Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Testing and Inspection > Page 10046 Dimmer Switch: Service and Repair INSTRUMENT PANEL DIMMER SWITCH Removal and Installation 1. Remove the driver side register. 2. Remove the headlamp switch and bezel as an assembly. - Disconnect the electrical connectors. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Testing and Inspection > Page 10047 3. Release the 2 tabs and remove the instrument panel dimmer switch. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Interior Lamp - Front Dome Lamp: Service and Repair Interior Lamp - Front INTERIOR LAMP - FRONT Removal and Installation 1. NOTE: Use a small screwdriver to pry open the garage door opener bin. Open the rear overhead console storage or garage door opener bin to access the retaining screw. Remove the screw. 2. Pull the front of the overhead console down and remove the console from the console retaining clips. - Disconnect the electrical connector(s). 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Interior Lamp - Front > Page 10052 Dome Lamp: Service and Repair Interior Lamp - Rear INTERIOR LAMP - REAR Removal and Installation 1. Remove the rear interior lamp lens. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Interior Lamp - Front > Page 10053 2. Release the 2 retaining clips (through the access holes) and remove the rear interior lamp assembly. - Disconnect the electrical connector. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front View 151-21 (Driver Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 10058 View 151-22 (Passenger Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 10059 View 151-24 (Left Rear Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 10060 View 151-23 (Right Rear Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 10061 Door Switch: Locations View 151-21 (Driver Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 10062 View 151-22 (Passenger Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 10063 View 151-24 (Left Rear Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 10064 View 151-23 (Right Rear Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 10065 View 151-25 (Liftgate) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 10066 View 151-25 (Liftgate) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch C479 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 10069 C478 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 10070 C526 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 10071 C602 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 10072 Door Switch: Diagrams C479 C478 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 10073 C526 C602 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 10074 C715 C820 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair Fog/Driving Lamp Bulb: Service and Repair FOG LAMP BULB Removal and Installation WARNING: The fog lamp bulb contains gas under pressure. The bulb may shatter if the glass envelope is scratched or if the bulb is dropped. Handle the bulb only by its base. Avoid touching the glass envelope. Failure to follow these instructions may result in personal injury. NOTE: - The fog lamp bulb should not be removed from the fog lamp assembly until just before a new bulb is installed. Removing the bulb for an extended period of time may affect fog lamp bulb performance. Contaminants may enter the fog lamp assembly where they can settle on the lens and reflector. Never turn on the fog lamps with the bulb removed from the fog lamp assembly. - Make sure the headlamp switch and ignition switch are in the OFF position. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the electrical connector and remove the fog lamp bulb. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 10082 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Application and ID Hazard Warning Flasher: Application and ID The flasher function for this vehicle is provided by the Smart Junction Box (SJB). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair Headlamp Bulb: Service and Repair HEADLAMP BULB Explorer, Explorer Sport Trac Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > Page 10091 Mountaineer Removal and Installation WARNING: The headlamp bulb contains gas under pressure. The bulb may shatter if the glass envelope is scratched or if the bulb is dropped. Handle the bulb only by its base. Avoid touching the glass envelope. Failure to follow these instructions may result in personal injury. NOTE: The headlamp bulb should not be removed from the headlamp assembly until just before a new bulb is installed. Removing the bulb for an extended period of time may affect headlamp bulb performance. Contaminants may enter the headlamp assembly where they can settle on the lens and reflector. Never turn on the headlamps with the bulb removed from the headlamp assembly. 1. Remove the headlamp assembly. 2. Rotate the headlamp bulb one-eighth turn counterclockwise and remove the headlamp bulb. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations > Illumination Dimmer Switch View 151-11 (behind Dash Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations > Illumination Dimmer Switch > Page 10096 View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch C202 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch > Page 10099 C2298 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 10100 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 10101 Headlamp Dimmer Switch: Service and Repair Steering Column Multifunction Switch Steering Column Multifunction Switch Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column can result. 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the 2 screws and the steering column opening cover. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 10102 3. Remove the 3 screws and the upper and lower steering column shroud. 4. Disconnect the multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the multi-function switch. 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations View 151-11 (behind Dash Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 10106 C205 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 10107 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 10108 Headlamp Switch: Service and Repair HEADLAMP SWITCH Removal and Installation 1. Remove the driver side register. 2. Remove the headlamp switch and bezel as an assembly. - Disconnect the electrical connectors. 3. Remove the 3 screws and the headlamp switch. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations View 151-30 (Steering Wheel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions License Plate Lamp: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10117 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10118 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10119 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10120 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10121 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10122 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10123 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10124 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10125 License Plate Lamp: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10126 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10127 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10128 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10129 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10130 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10131 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10132 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10133 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10134 License Plate Lamp: Connector Views C452 C462 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10135 License Plate Lamp: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 92-3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10136 92-4 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. See: Diagrams/Components/Component Location Views Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions Marker Lamp: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10141 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10142 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10143 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10144 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10145 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10146 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10147 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10148 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10149 Marker Lamp: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10150 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10151 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10152 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10153 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10154 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10155 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10156 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10157 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10158 Marker Lamp: Connector Views C1127 C1126 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10159 C481 C482 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10160 Marker Lamp: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 92-3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10161 92-4 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. See: Diagrams/Components/Component Location Views Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Page 10162 Marker Lamp: Service and Repair SIDE MARKER LAMP Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the socket from the side marker lamp. 3. Remove the 2 nuts and the side marker lamp. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 10167 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 10172 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 10176 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 10180 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations View 151-11 (behind Dash Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 10185 C286 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 10186 Ambient Light Sensor: Service and Repair LIGHT SENSOR Removal and Installation 1. Position the top portion of the lower center instrument panel finish panel rearward. 2. Remove the upper center instrument panel finish panel. - Disconnect the electrical connector. 3. Remove the 2 screws and the light sensor. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations View 151-5 (Engine, Front - 4.0L) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 10190 C167 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 10191 Backup Lamp Switch: Testing and Inspection Digital Transmission Range (TR) Sensor Diagnosis Chart Digital Transmission Range (TR) Sensor Diagnosis Chart Wiggle Test Information for Open/Shorts ^ TR4, TR3A, TR2 and TR1 are all closed in PARK. PARK is a good position to check for intermittent open circuits (with scan tool monitoring TRD). ^ TR4, TR3A, TR2 and TR1 are all open in OVERDRIVE, so OVERDRIVE is a good position to check for shorts to ground. To determine the shorted components while observing TRD, unplug the TR and determine if the short goes away. If the short is still present unplug the transmission harness and determine if the short goes away. If the short is still present, then the short is in the PCM or vehicle harness. Remove the suspect circuit(s) wire terminal from the PCM connector. If the short is still present, then the PCM has an internal failure, otherwise the failure is in the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations View 151-1 (Engine Compartment - 4.0L, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 10195 C278 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 10196 Brake Light Switch: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical BPP Switch The BPP switch is sometimes referred to stoplamp switch. The BPP switch provides a signal to the PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as follows: - to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied. - to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is then broadcast over the network to be received by the PCM. - to the ABS traction control/stability assist module. The ABS module interprets the BPP switch input along with other ABS inputs and generates an output called the driver brake application (DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 10197 Brake Light Switch: Service and Repair STOPLAMP SWITCH Removal and Installation CAUTION: Do not remove or repair the brake pedal, brake booster or master cylinder without first removing the stoplamp switch. Do not install the stoplamp switch without the brake pedal arm secured to the brake booster push rod. Do not pull or push on the brake pedal when removing or installing the stoplamp switch, as misadjustment or damage to the switch may occur. 1. Disconnect the stoplamp switch electrical connector. 2. Rotate the stoplamp switch 45 degrees clockwise and remove the stoplamp switch. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Console Lamp Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door Console Lamp Switch: Service and Repair Door Ajar Switch - Front Door DOOR AJAR SWITCH - FRONT DOOR Removal and Installation 1. Remove the front door latch. 2. Disconnect the front door ajar switch electrical connector. 3. Release the locking tab and rotate the front door ajar switch counterclockwise and remove the switch from the front door latch. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Console Lamp Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 10202 Console Lamp Switch: Service and Repair Door Ajar Switch - Rear Door DOOR AJAR SWITCH - REAR DOOR Removal and Installation 1. Remove the rear door latch. 2. Release the locking tab, rotate the rear door ajar switch counterclockwise and remove the switch from the rear door latch. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Console Lamp Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 10203 Console Lamp Switch: Service and Repair Door Ajar Switch - Liftgate DOOR AJAR SWITCH - LIFTGATE Removal and Installation 1. Remove the liftgate latch. 2. Release the locking tab, rotate the liftgate ajar switch counterclockwise and remove the ajar switch form the liftgate latch. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Console Lamp Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 10204 Console Lamp Switch: Service and Repair Door Ajar Switch - Liftgate Glass DOOR AJAR SWITCH - LIFTGATE GLASS Removal and Installation 1. Remove the liftgate window latch. 2. Rotate the liftgate window ajar switch counterclockwise and remove the ajar switch from the liftgate window latch. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front View 151-21 (Driver Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 10209 View 151-22 (Passenger Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 10210 View 151-24 (Left Rear Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 10211 View 151-23 (Right Rear Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 10212 Door Switch: Locations View 151-21 (Driver Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 10213 View 151-22 (Passenger Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 10214 View 151-24 (Left Rear Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 10215 View 151-23 (Right Rear Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 10216 View 151-25 (Liftgate) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 10217 View 151-25 (Liftgate) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch C479 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 10220 C478 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 10221 C526 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 10222 C602 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 10223 Door Switch: Diagrams C479 C478 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 10224 C526 C602 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Ajar Switch > Page 10225 C715 C820 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Illumination Dimmer Switch View 151-11 (behind Dash Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Illumination Dimmer Switch > Page 10230 View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch C202 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch > Page 10233 C2298 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 10234 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 10235 Headlamp Dimmer Switch: Service and Repair Steering Column Multifunction Switch Steering Column Multifunction Switch Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column can result. 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the 2 screws and the steering column opening cover. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 10236 3. Remove the 3 screws and the upper and lower steering column shroud. 4. Disconnect the multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the multi-function switch. 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations View 151-11 (behind Dash Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 10240 C205 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 10241 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 10242 Headlamp Switch: Service and Repair HEADLAMP SWITCH Removal and Installation 1. Remove the driver side register. 2. Remove the headlamp switch and bezel as an assembly. - Disconnect the electrical connectors. 3. Remove the 3 screws and the headlamp switch. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations View 151-30 (Steering Wheel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 10249 C202 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 10250 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 10251 Turn Signal Switch: Service and Repair Steering Column Multifunction Switch Steering Column Multifunction Switch Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column can result. 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the 2 screws and the steering column opening cover. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 10252 3. Remove the 3 screws and the upper and lower steering column shroud. 4. Disconnect the multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the multi-function switch. 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions Tail Lamp: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10257 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10258 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10259 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10260 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10261 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10262 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10263 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10264 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10265 Tail Lamp: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10266 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10267 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10268 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10269 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10270 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10271 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10272 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10273 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10274 Tail Lamp: Connector Views C412 C415 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10275 C418 C419 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10276 Tail Lamp: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 92-3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10277 92-4 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. See: Diagrams/Components/Component Location Views Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions Trailer Lamps: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10282 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10283 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10284 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10285 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10286 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10287 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10288 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10289 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10290 Trailer Lamps: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10291 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10292 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10293 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10294 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10295 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10296 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10297 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10298 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10299 Trailer Lamps: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 95-1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10300 95-2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 10301 95-3 Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Component Location Views. See: Diagrams/Components/Component Location Views Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) 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 INSPECTION AND VERIFICATION 1. Verify the customer concern. 2. Verify the exterior lighting system of the vehicle is operating correctly. If not, refer to the appropriate pinpoint test. 3. Visually inspect the following for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical Battery junction box (BJB) fuse(s): 13 (30A) (trailer tow battery charge relay - switched) - 17 (30A) (trailer brake control module) - Smart junction box (SJB) fuse(s): 7 (15A) (trailer stop/turn lamps) - 12 (5A) (trailer tow battery charge relay coil) - 16 (10A) (trailer reversing lamps) - 25 (15A) (trailer parking lamps and trailer brake control module) - SJB - Circuity - Trailer 4. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. NOTE: - Make sure the headlamp switch is in the OFF position. - Make sure the multifunction switch is in the LOW BEAM position. 5. NOTE: Make sure to use the latest scan tool release software. If the cause is not visually evident, connect the scan tool to the data link connector (DLC). 6. NOTE: The vehicle communication module (VCM) LED prove-out confirms power and ground from the DLC are provided to the VCM. If the scan tool does not communicate with the VCM: Check the VCM connection to the vehicle. - Check the scan tool connection to the VCM. - Refer to Information Bus (Module Communications Network), No Power To The Scan Tool, to diagnose no communication with the scan tool. 7. If the scan tool does not communicate with the vehicle: - Verify the ignition key is in the ON position. - Verify the scan tool operation with a known good vehicle. - Refer to Information Bus (Module Communications Network) to diagnose no response from the powertrain control module (PCM). 8. Carry out the network test. - If the scan tool responds with no communication with the SJB, refer to Information Bus (Module Communications Network). - If the network test passes, retrieve and record the continuous memory DTCs. 9. Clear the continuous DTCs and carry out the self-test diagnostics for the SJB. 10. If the DTCs retrieved are related to the concern, go to the Smart Junction Box (SJB) Diagnostic Trouble Code (DTC) Chart. For all other DTCs, refer to Body Control Systems (Multifunction Electronic Control Module). See: Diagnostic Trouble Code Descriptions 11. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related Diagnostic Procedures NOTE: When diagnosing the trailer tow lamps, begin by verifying that the vehicle lamp systems are all functioning correctly with the trailer disconnected. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10304 B2070 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10305 Trailer Lamps: Symptom Related Diagnostic Procedures Symptom Chart (Part 1) Symptom Chart (Part 2) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10306 Trailer Lamps: Pinpoint Tests Test V: The Trailer Lamps Are Inoperative - Trailer Parking Lamps PINPOINT TEST V: THE TRAILER LAMPS ARE INOPERATIVE - TRAILER PARKING LAMPS V1-V2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10307 V2-V3 Normal Operation Voltage to the trailer parking lamps is supplied by the smart junction box (SJB) through circuit CAT17 (BN). Possible Causes - Fuse - Circuit CAT17 (BN) open - Trailer - SJB Test W: The Trailer Lamps Are Inoperative - Trailer Reversing Lamps PINPOINT TEST W: THE TRAILER LAMPS ARE INOPERATIVE - TRAILER REVERSING LAMPS W1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10308 W1-W3 Normal Operation Voltage to the trailer reversing lamps is supplied by the smart junction box (SJB) through circuit CAT16 (GY/BN). Possible Causes - Fuse - Circuit CAT16 (GY/BN) open - Trailer - SJB Test X: The Individual Trailer Lamp Is Inoperative - LH Trailer Stoplamp PINPOINT TEST X: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - LH TRAILER STOPLAMP Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10309 X1-X2 X3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10310 Normal Operation Voltage to the LH trailer stoplamp is supplied by the smart junction box (SJB) through circuit CAT06 (YE). DTC B2070 - is a continuous DTC that sets when the SJB detects a short to ground from the LH trailer turn/stoplamp voltage supply circuit. The self-test must be run after the repair in order for the SJB to enable the output for the LH trailer turn/stoplamp voltage supply. Possible Causes - Circuit CAT06 (YE) open or short to ground - Trailer - SJB Test Y: The Individual Trailer Lamp Is Inoperative - RH Trailer Stoplamp PINPOINT TEST Y: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - RH TRAILER STOPLAMP Y1-Y2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10311 Y2-Y3 Normal Operation Voltage to the RH trailer stoplamp is supplied by the smart junction box (SJB) through circuit CAT09 (GN). DTC B2070 - is a continuous DTC that sets when the SJB detects a short to ground from the RH trailer turn/stoplamp voltage supply circuit. The self-test must be run after the repair in order for the SJB to enable the output for the RH trailer turn/stoplamp voltage supply. Possible Causes - Circuit CAT09 (GN) open or short to ground - Trailer - SJB Test Z: The Trailer Lamps Are On Continuously PINPOINT TEST Z: THE TRAILER LAMPS ARE ON CONTINUOUSLY Z1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10312 Z1-Z3 Normal Operation Voltage to the trailer tow lamps is controlled by the smart junction box (SJB). Circuits CAT06 (YE) and CAT09 (GN) supply voltage to the trailer tow LH and RH stoplamps, respectively. Possible Causes - Circuit CAT06 (YE) short to voltage - Circuit CAT09 (GN) short to voltage - Trailer - SJB Tests AA: The Trailer Battery Charging Is Inoperative/Does Not Operate Correctly PINPOINT TEST AA: THE TRAILER BATTERY CHARGING IS INOPERATIVE/DOES NOT OPERATE CORRECTLY Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10313 AA1-AA3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10314 AA3-AA4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10315 AA4-AA5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10316 AA5 Continued Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10317 AA6-AA8 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10318 AA8-AA10 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10319 AA10-AA11 Normal Operation The trailer battery charge relay coil receives voltage from the smart junction box (SJB) fuse 12 (5A) through circuit CBP12 (GN/WH) when the ignition switch is in the RUN or ACC position. Ground for the trailer battery charge relay coil is supplied through circuit GD120 (BK/GN). The battery junction box (BJB) fuse 13 (30A) supplies voltage to the trailer battery charge relay through circuit SSB13 (GY/RD). When the trailer battery charge relay is energized, the voltage is routed to the trailer tow connector through circuit CAT14 (OG). Possible Causes - Fuse - Circuit CAT14 (OG) open or short to voltage - Circuit CBP12 (GN/WH) open or short to voltage - Circuit GD120 (BK/GN) open - Circuit SSB13 (GY/RD) open - Trailer battery charge relay - Trailer - SJB Tests AB: The Trailer Electric Brakes Are Inoperative/Do Not Operate Correctly PINPOINT TEST AB: THE TRAILER ELECTRIC BRAKES ARE INOPERATIVE/DO NOT OPERATE CORRECTLY Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10320 AB1-AB2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10321 AB3-AB5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10322 AB6-AB8 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10323 AB9 Normal Operation The trailer electric brake controller is provided voltage at all times by the battery junction box (BJB) fuse 17 (30A) through circuit SBB17 (RD). Ground for the trailer electric brake controller is provided through circuit GD138 (BK/WH). The trailer electric brake controller receives voltage from the stoplamp switch through circuit CCB08 (VT/WH) when the brake pedal is applied. When requested, the trailer electric brake controller provides voltage to the trailer tow connector through circuit CAT19 (BU). Possible Causes - Fuse - Circuit CAT17 (BN) open - Circuit CAT19 (BU) open, short to ground, or short to voltage - Circuit CCB08 (VT/WH) open - Circuit GD138 (BK/WH) open - Circuit SBB17 (RD) open - Trailer electric brake controller - Trailer Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Page 10324 Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 10328 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Application and ID Turn Signal Flasher: Application and ID The flasher function for this vehicle is provided by the Smart Junction Box (SJB). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp, Left Rear C413 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp, Left Rear > Page 10337 C416 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp, Left Rear > Page 10338 Turn Signal Lamp: Diagrams Park/Turn Lamp, Left Front C1023 C1115 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp, Left Rear > Page 10339 C1108 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp, Left Rear > Page 10340 Turn Signal Lamp: Diagrams C413 C416 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp, Left Rear > Page 10341 C1023 C1115 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp, Left Rear > Page 10342 C1108 C1109 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp, Left Rear > Page 10343 C4032 C1043 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp, Left Rear > Page 10344 C1116 C4035 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 10348 C202 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 10349 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 10350 Turn Signal Switch: Service and Repair Steering Column Multifunction Switch Steering Column Multifunction Switch Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column can result. 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the 2 screws and the steering column opening cover. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 10351 3. Remove the 3 screws and the upper and lower steering column shroud. 4. Disconnect the multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the multi-function switch. 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Vanity Mirror Lamp, Left C907 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Vanity Mirror Lamp, Left > Page 10356 C906 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Rear Window Defrost Relay Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Rear Window Defrost Relay > Page 10363 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Testing and Inspection > Rear Window Defrost Relay Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Testing and Inspection > Rear Window Defrost Relay > Page 10366 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Rear Window Defrost Relay Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Rear Window Defrost Relay > Page 10372 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Testing and Inspection > Rear Window Defrost Relay Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Testing and Inspection > Rear Window Defrost Relay > Page 10375 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch View 151-21 (Driver Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 10381 View 151-22 (Passenger Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 10382 View 151-24 (Left Rear Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 10383 View 151-23 (Right Rear Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch Power Window Switch: Diagrams Master Window Adjust Switch C504A C504B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 10386 C701 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 10387 C604 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 10388 C801 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 10391 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 10392 Power Window Switch: Service and Repair WINDOW CONTROL SWITCH Removal and Installation 1. Remove the interior door handle cover. 2. Lift the window control switch bezel upward to release the clips. 3. Disconnect the window control switch electrical connectors from the window control switch. 4. Disconnect the window control switch from the window control switch bezel to remove. 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair WINDOW REGULATOR MOTOR - FRONT DOOR Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair > Page 10398 Part 2 Exploded View Removal and Installation 1. Remove the front door window regulator. 2. Remove the 3 front door window regulator motor bolts. - To install, tighten to 7 Nm (62 lb-in). 3. Remove the front door window regulator motor. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair Rear Door Window Motor: Service and Repair WINDOW REGULATOR MOTOR - REAR DOOR Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair > Page 10402 Part 2 Exploded View Removal and Installation 1. Remove the interior moulding. 2. Remove the rear door trim panel and weather shield. 3. Remove the 3 window regulator motor bolts. - To install, tighten to 7 Nm (62 lb-in). 4. Remove the window regulator motor. 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Master Window Adjust Switch View 151-21 (Driver Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 10407 View 151-22 (Passenger Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 10408 View 151-24 (Left Rear Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 10409 View 151-23 (Right Rear Door) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch Power Window Switch: Diagrams Master Window Adjust Switch C504A C504B Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 10412 C701 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 10413 C604 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 10414 C801 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 10417 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Page 10418 Power Window Switch: Service and Repair WINDOW CONTROL SWITCH Removal and Installation 1. Remove the interior door handle cover. 2. Lift the window control switch bezel upward to release the clips. 3. Disconnect the window control switch electrical connectors from the window control switch. 4. Disconnect the window control switch from the window control switch bezel to remove. 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Window Glass - Rear, Fixed Back Window Glass: Service and Repair Window Glass - Rear, Fixed WINDOW GLASS - REAR, FIXED Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Window Glass - Rear, Fixed > Page 10424 Part 2 Exploded View Removal and Installation 1. Remove the cab rear panel. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Window Glass - Rear, Fixed > Page 10425 2. Remove the 15 rear window glass mounting nuts. - To install, tighten to 3 Nm (27 lb-in). 3. Remove the rear window glass. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Window Glass - Rear, Fixed > Page 10426 Back Window Glass: Service and Repair Window Glass - Rear, Power WINDOW GLASS - REAR, POWER Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Window Glass - Rear, Fixed > Page 10427 Part 2 Exploded View Removal and Installation 1. Remove the rear window glass regulator. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Window Glass - Rear, Fixed > Page 10428 2. Remove both C-pillar upper trim panels. 3. Remove the 12 rear window glass mounting nuts. - To install, tighten to 3 Nm (27 lb-in). 4. Remove the rear window glass. 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair Front Door Window Glass Weatherstrip: Service and Repair DOOR GLASS TOP RUN - FRONT Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Page 10433 Part 2 Exploded Views Removal and Installation 1. Remove the front door window glass. 2. Remove the exterior moulding. 3. Remove the front door glass top run channel assembly bolt. - To install, tighten to 12 Nm (9 lb-ft). 4. Remove the front door glass top run channel assembly through the top opening of the front door. 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair WINDOW GLASS - LIFTGATE Material Material Removal and Installation 1. If installing a new liftgate window glass, remove the rear window wiper motor. 2. Position the liftgate trim panel aside to access the liftgate window glass electrical connectors and the 2 liftgate window glass hinge-to-glass screws. 3. Disconnect the liftgate window glass electrical connectors. 4. CAUTION: Open and support the liftgate window glass before removing the liftgate window glass struts. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Page 10437 Remove the liftgate window glass struts. To avoid breaking the liftgate window glass, disconnect the liftgate window glass struts from the liftgate window glass before disconnecting the liftgate window glass struts from the rear liftgate. 5. Remove the 2 liftgate hinge-to-glass screws. - Apply threadlock into the liftgate window glass hinge-to-glass bolt hole, making sure that the threadlock is on the threads. - To install, tighten to 10 Nm (89 lb-in). 6. With the help of an assistant, remove the liftgate window glass. 7. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair Quarter Window Glass: Service and Repair WINDOW GLASS - REAR QUARTER Special Tool(s) Special Tool(s) Material Material Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Page 10441 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. Failure to follow these instructions may result in personal injury. 1. Remove the rear quarter trim panel. 2. Remove the wiring harness brackets. 3. NOTE: Locating tabs need to be cut through in order to remove the rear quarter window glass. The new rear quarter window glass will be equipped with new locating tabs. Lubricate the urethane adhesive with water to aid the special tool when cutting. 4. Using the special tool, cut the urethane adhesive from the rear quarter window glass starting at the top center, working toward the bottom corners to remove the rear quarter glass. 5. Using a soft brush or vacuum, remove any foreign material or dirt from the pinchweld. Installation CAUTION: After installing the urethane installed glass, the vehicle should not be driven until the urethane adhesive has cured. Refer to the drive away chart time for the cure time as temperatures and humidity vary. Inadequate curing of the urethane adhesive will adversely affect the strength of the urethane bond. 1. Dry fit the rear quarter window glass, making alignment marks with tape or non-staining grease pencil. 2. NOTE: Avoid scratching the pinch weld. For minor scratches or exposed metal on the pinch weld, see manufacturer's recommendations. Using an appropriate tool, trim the urethane adhesive leaving a 1-mm to 2-mm base of original equipment urethane on the pinch weld. 3. Clean the inside of the rear quarter glass encapsulation rim surface with glass cleaner, making sure the area is clean. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Page 10442 4. CAUTION: Be sure to use the same brand and cure-rate products for the adhesive and primer. Do not mix different brands of urethane and primer. Refer to the Material Chart in this procedure. NOTE: Sika uses the same black primer for the glass and pinch weld area. If installing a new rear quarter window glass, apply urethane glass primer according to manufacturer's instructions. Allow at least 6 minutes to dry. 5. Cut the urethane adhesive applicator tip to specification. 6. NOTE: Use either a high-ratio, electric or battery-operated caulk gun that will apply the urethane with less effort and continuous bead. Use caution when applying urethane adhesive. Apply to the outside edges of the locating tabs on the glass surface. Start at the bottom and work around to the sides of the rear quarter window glass. 7. Install the rear quarter window glass, aligning it to the marks previously made. 8. Install the wiring harness brackets. 9. Install the rear quarter trim panel. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair Rear Door Window Glass Weatherstrip: Service and Repair DOOR GLASS TOP RUN - REAR Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Page 10447 Part 2 Exploded View Removal and Installation 1. Remove the rear door window glass. 2. Remove the exterior moulding. 3. Remove the rear door glass top run assembly bolt. - To install, tighten to 12 Nm (9 lb-ft). 4. Remove the rear door glass top run channel assembly. - Remove the rear door glass top run channel assembly through the top opening of the rear door. 5. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair Front Door Window Regulator: Service and Repair WINDOW REGULATOR - FRONT DOOR Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Page 10452 Part 2 Exploded View Removal and Installation 1. Remove the front door trim panel. 2. Remove the front door speaker. 3. Remove the exterior mirror front door weather shield. 4. Disconnect the exterior mirror electrical connector. 5. Release the 3 door wiring harness pin-type retainers. 6. Remove the front door weather shield. 7. Remove the door trim panel reinforcement screw. 8. Remove the door trim panel reinforcement. 9. CAUTION: Make sure the holes in the glass bracket do not become enlarged during the rivet removal process. If the holes become enlarged, the new rivets may become loose, resulting in a clicking noise concern. NOTE: Use a 4.5 mm (0.1772 in) drill bit to drill out the glass-to-regulator rivets. Remove the 2 front door window glass-to-regulator rivets. Position the front door window glass as necessary to access the front door window glass-to-regulator rivets. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Page 10453 10. Secure the front door glass in the full up position with tape. 11. Disconnect the window regulator motor electrical connector. 12. Remove the 5 window regulator assembly nuts. - To install, tighten to 10 Nm (89 lb-in). 13. Remove the window regulator assembly. 14. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair Rear Door Window Regulator: Service and Repair WINDOW REGULATOR - REAR DOOR Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Page 10457 Part 2 Exploded View Removal and Installation 1. Remove the rear door trim panel. 2. Remove the rear door speaker. 3. Remove the interior moulding. 4. Remove the rear door weather shield. 5. CAUTION: Make sure the hole in the glass bracket does not become enlarged during the rivet removal process. If the hole becomes enlarged, the new rivet may become loose, resulting in a clicking noise concern. NOTE: Use a 4.5 mm (0.1772 in) drill bit to drill out the glass-to-regulator rivets. Remove the rear door window glass-to-regulator rivet. Position the rear door window glass as necessary to access the rear door window glass-to-regulator rivet. 6. Secure the rear door window glass in the full up position with tape. 7. Disconnect the window regulator motor electrical connector. 8. Remove the 2 window regulator nuts. - To install, tighten to 10 Nm (89 lb-in). 9. Remove the 3 window regulator motor bracket nuts. - To install, tighten to 10 Nm (89 lb-in). 10. Remove the window regulator assembly. 11. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Diagrams > Heated Windshield, Left C1531 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Diagrams > Heated Windshield, Left > Page 10462 C1532 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures Windshield: Procedures WINDSHIELD RESEAL Material Material 1. Remove the RH and LH side A-pillar trim panel. 2. Remove the sun visors, retainers and, if equipped, the overhead console. 3. If equipped, remove the roof opening panel trim. 4. Remove the interior mirror. 5 Lower the front portion of the headliner. 6. Remove the wiper pivot arms. 7. Remove the cowl panel grille. 8. Clean the edge formed by the existing urethane and the glass on the inside at the top, sides and outside on the bottom of the windshield with glass cleaner. 9. Cut the urethane applicator tip to specification. 10. NOTE: Use either a high-ratio electric or battery-operated caulk gun that will apply the urethane with less effort and a continuous bead. Apply a bead of urethane adhesive to the cleaned area. 11. NOTE: Make sure that all gaps in the urethane adhesive are smoothed into one continuous bead. Backfill the urethane application and clean the excess. 12. CAUTION: The urethane adhesive must cure for a minimum of one hour before testing for air or water leaks. After the urethane has cured, check the windshield seal for air or water leaks through the urethane adhesive bead and add urethane adhesive as necessary. 13. Install the cowl panel grille. 14. Install the wiper pivot arms. 15. Raise the headliner and position. 16. If equipped, install the roof opening panel trim. 17. Install the interior mirror. 18. Install the sun visors, retainers and, if equipped, the overhead console. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures > Page 10465 19. Install the RH and LH side A-pillar trim panels. 20. Clean the exterior and interior of the windshield glass with glass cleaner. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures > Page 10466 Windshield: Removal and Replacement WINDSHIELD GLASS Special Tool(s) Special Tool(s) Material Material Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures > Page 10467 Removal WARNING: To prevent glass splinters from entering the eyes or cutting hands, wear safety glasses and heavy gloves when cutting and removing the glass from the vehicle. 1. Remove the RH and LH side A-pillar trim panels. 2. Remove the sun visors and retainers and, if equipped, the overhead console. 3. If equipped, remove the roof opening panel trim. 4. Remove the interior mirror. 5. Lower the front portion of the headliner. 6. Remove the wiper pivot arms. 7. Remove the cowl panel grille. 8. NOTE: LH shown, RH similar. If equipped, disconnect the heated windshield electrical connectors. Disconnect the connector. - Remove the connector from the retainer. - Remove the connector from the stud. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures > Page 10468 9. NOTE: LH shown, RH similar. Lower the setting blocks. Use a flat screwdriver to release the setting block and lower. 10. NOTE: Lubricate the urethane adhesive with water to aid the special tool when cutting. Using the special tool, cut the urethane adhesive from the windshield glass starting at the top center and working toward the bottom corners. 11. Using the special tool, distance the windshield from the body. 12. NOTE: - Removing the windshield glass requires more than one technician. - Be sure not to scratch the pinch weld while removing windshield glass. Using the special tool, cut the remaining urethane adhesive and remove the window glass. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures > Page 10469 13. Using a soft brush or vacuum, remove any dirt and foreign material from the pinch weld. Installation 1. NOTE: Raise the setting block until flush with top. Lock the blocks into place after windshield is installed. Raise the setting blocks. 2. Dry fit the windshield. Make alignment marks with tape or non-staining pencil. 3. NOTE: Avoid scratching the pinch weld. For minor scratches or exposed metal on the pinch weld, see manufacturer's recommendations. Using an appropriate tool, trim the urethane adhesive leaving a 1-mm to 2-mm base of original equipment urethane on the pinch weld. 4. CAUTION: Be sure to use the same brand and cure-rate products for the adhesive and primer. Do not mix different brands of urethane and primer. Refer to the Material Chart in this procedure. NOTE: Sika uses the same black primer for the glass and pinch weld area. Apply urethane glass primer according to manufacturer's instructions. Allow at least 6 minutes to dry. 5. Cut the urethane applicator tip to specification. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures > Page 10470 6. NOTE: Use either a high-ratio, electric or battery-operated caulk gun that will apply the urethane with less effort and continuous bead. Apply urethane adhesive on top of the existing trimmed urethane adhesive bead on the pinch weld. Make sure that all gaps in the urethane adhesive are smoothed into one continuous bead. 7. NOTE: Inspect the flat foil connectors at the bottom of the new windshield for damage prior to installation. Do not install a windshield with damaged flat foil connectors. Install the windshield by aligning it to the marks previously made. 8. CAUTION: When installing urethane-installed glass parts, the vehicle must not be driven until the urethane has cured. Adequate cure time is specified on the drive away chart for each urethane product as the temperatures and humidity vary. Inadequate or incorrect curing can adversely affect the retention of the windshield. After the urethane has cured, check the windshield glass seal for air or water leaks through the urethane adhesive bead and add urethane adhesive as necessary. 9. NOTE: Follow the same routing for the electrical connector that was used during removal. If equipped, connect the heated windshield electrical connectors. 10. Install the cowl panel grille. 11. Install the wiper pivot arms. 12. Raise the headliner and position. 13. If equipped, install the roof opening panel trim. 14. Install the interior mirror. 15. Install the sun visors, retainers and, if equipped, the overhead console. 16. Install the RH and LH side A-pillar trim panels. 17. Clean the exterior and interior of the windshield glass with glass cleaner. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations View 151-25 (Liftgate) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 10476 C4323 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 10480 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations View 151-2 (Engine Compartment - 4.0L, (2 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 10485 C138 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Multifunction Switch View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Multifunction Switch > Page 10490 View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Multifunction Switch C202 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Multifunction Switch > Page 10493 C2347 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 10496 Windshield Washer Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 10497 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 10498 Windshield Washer Switch: Service and Repair Steering Column Multifunction Switch Steering Column Multifunction Switch Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column can result. 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the 2 screws and the steering column opening cover. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 10499 3. Remove the 3 screws and the upper and lower steering column shroud. 4. Disconnect the multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the multi-function switch. 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 10503 C202 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch, Wiper/Washer Portion Wiper Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch, Wiper/Washer Portion > Page 10506 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch, Wiper/Washer Portion > Page 10507 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 10508 Wiper Switch: Service and Repair Steering Column Multifunction Switch Steering Column Multifunction Switch Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column can result. 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the 2 screws and the steering column opening cover. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 10509 3. Remove the 3 screws and the upper and lower steering column shroud. 4. Disconnect the multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the multi-function switch. 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations View 151-2 (Engine Compartment - 4.0L, (2 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 10513 C138 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations View 151-1 (Engine Compartment - 4.0L, (1 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations > Page 10517 C1397 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair Windshield Washer Pump: Service and Repair WASHER PUMP Removal and Installation WARNING: Windshield washer solution contains methanol, which is poisonous. Observe all cautions and warnings indicated on the label of the container. Failure to follow these instructions could result in personal injury. CAUTION: - When servicing the windshield washer pump be careful not to damage the windshield washer pump seal. - Do not operate the windshield washer pump before filling the windshield washer reservoir. Failure to do so could result in premature pump failure. 1. Disconnect the windshield washer reservoir hoses. 2. Disconnect the windshield washer pump electrical connector. 3. Remove the windshield washer pump. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair Windshield Washer Reservoir: Service and Repair WASHER RESERVOIR Removal and Installation WARNING: Windshield washer solution contains methanol, which is poisonous. Observe all cautions and warnings indicated on the label of the container. Failure to follow these instructions could result in personal injury. CAUTION: - When servicing the windshield washer pump, be careful not to damage the windshield washer pump seal. - Do not operate the windshield washer pump before filling the windshield washer reservoir. Failure to do so could result in premature pump failure. 1. Remove the air cleaner assembly. 2. Remove the RH front fender splash shield. 3. Disconnect the windshield washer pump electrical connector. 4. Disconnect the windshield washer solvent level electrical connector. NOTE: If necessary, drain the windshield washer reservoir after removal. 5. Disconnect the windshield washer reservoir hoses. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Page 10524 6. Remove the top bolt. - To install, tighten to 5 Nm (44 lb-in). 7. Remove the side bolt. - To install, tighten to 5 Nm (44 lb-in). 8. Remove the bolt. - To install, tighten to 5 Nm (44 lb-in). 9. Remove the windshield washer pump reservoir. 10. Transfer components as necessary. 11. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Multifunction Switch View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Multifunction Switch > Page 10529 View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Multifunction Switch C202 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Multifunction Switch > Page 10532 C2347 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 10535 Windshield Washer Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 10536 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 10537 Windshield Washer Switch: Service and Repair Steering Column Multifunction Switch Steering Column Multifunction Switch Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column can result. 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the 2 screws and the steering column opening cover. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 10538 3. Remove the 3 screws and the upper and lower steering column shroud. 4. Disconnect the multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the multi-function switch. 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments Wiper Arm: Adjustments WIPER BLADE AND PIVOT ARM ADJUSTMENT - WINDSHIELD 1. Cycle and park the windshield wipers. 2. Verify the distance between the center of the (1) RH windshield wiper blade and the (3) bottom of the windshield glass to be sure the distance is within specification. 3. Verify the distance between the center of the (2) LH windshield wiper blade and the (3) bottom of the windshield glass to be sure the distance is within specification. 4. If the distance is not within specification, remove the windshield wiper pivot arm and reposition to specification. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Pivot Arm - Front Wiper Arm: Service and Repair Wiper Pivot Arm - Front WIPER PIVOT ARM - FRONT 1. Remove the wiper pivot arm. 1 Pull up on the pivot arm. 2 Pull out on the retaining tab and remove the pivot arm. 2. NOTE: The windshield wiper motor must be cycled to make sure that it is in the park position. If necessary, adjust the wiper pivot arms. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Pivot Arm - Front > Page 10544 Wiper Arm: Service and Repair Wiper Pivot Arm - Rear WIPER PIVOT ARM - REAR Removal 1. Remove the wiper pivot arm cover. 2. Remove the wiper pivot arm. 1 Remove the pivot arm nut. 2 Remove the wiper pivot arm. Installation 1. NOTE: Before installation, be sure that the rear window wiper motor is in the park position. Turn the wiper switch ON and OFF to allow the rear window wiper motor to cycle and stop in the park position. 2. Position the wiper pivot arm. 3. Install the pivot arm nut. - Tighten to 17 Nm (13 lb-ft). Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Pivot Arm - Front > Page 10545 4. Install the wiper pivot arm cover. 5. Operate the rear window wiper for one cycle to be sure that the pivot arm is in the correct position when the rear window wiper motor is in the park position. If the pivot arm is not in the correct position, remove the pivot arm and repeat Steps 1 through 4. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations View 151-25 (Liftgate) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 10549 C4323 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations View 151-2 (Engine Compartment - 4.0L, (2 Of 2)) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions Wiper Motor: Diagram Information and Instructions Introduction Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the diagrams to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one set. Other components that are connected to the circuits may not be shown unless they influence the circuit operation. Current Flow (1) Each set normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the diagram to ground at the bottom of the diagram. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in Power and Distribution Diagrams. Switch Positions (2) Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF). Splices (3) Splices directly connecting to the power distribution are best represented on the power distribution diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given to each off diagram where that particular splice can be best viewed. Component Referencing (4) Components on a diagram have a reference to a component location view or the diagram where it is shown completely. The reference is located to the right of each component. Component Names (5) Component names are placed on the right hand side of each component when possible. Descriptions of the internals of the component are also included when available. The diagram where the component appears in full is listed in the Index. The base part number for a component is listed in Vehicle/Diagrams. Internal Name and Function Identification Numbers (6) Some components on each diagram have internal symbols with an identification number located within it. You can identify the internal symbol or function by finding the corresponding number under the component name. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10555 Fuse and Relay Information Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are identified, numbered and named. Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper orientation. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10556 Power Distribution Power and Ground Distribution Diagrams shows the current feed circuits. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and the first component are shown. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10557 Ground Distribution Power and Ground Distribution Diagrams contains the diagrams that shows the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the component are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. C904 Component and Connector Information 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 when available. The harness causal number is located above the connector view and below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in set Component Location Charts. Component Location Views shows the components and their connecting wires as they can be found on the vehicle. Location information that can be found at the vehicle level will 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, along with a reference to the component location views. WARNINGS - Always wear safety glasses for eye protection. - Use safety stands whenever a procedure requires being under a vehicle. - Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by the procedure. - Set the parking brake when working on any vehicle. An automatic transmission should be in PARK. A manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. An explosion could occur. - Do not smoke when working on a vehicle. - To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose clothing. Symbols Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10558 Symbols Part 1 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10559 Symbols Part 2 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10560 Symbols Part 3 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10561 Symbols Part 4 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10562 Symbols Part 5 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10563 Wiper Motor: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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. Terminal not properly seated 1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal Check for unlocked terminals by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp 2 = Insulation not removed Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10564 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact Lock may be displaced into an unlocked position; pull on the connector to verify the lock. Deformed (enlarged) female terminals 1 = Enlarged Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10565 2 = Normal Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit. Electrical short inside the harness 1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short Solder coated wire pierced through the insulation of another circuit 4 = Grounding foil Electrical short within the harness Splice tape removed 1 = Intermittent short Splice covered 2 = Wire strand Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10566 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only) 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10567 3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together. NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder. - Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 6. Bend wire 1 back in a straight line. NOTE: Wait for solder to cool before moving wires. 7. Evenly position heat shrink tubing over wire repair. NOTE: Overlap tubing on both wires. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10568 8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter) 1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking care not to nick or cut wire strands. 3. Install heat shrink tubing. NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice. 4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10569 6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the wire in place, squeeze tool handles until ratchet releases. 10. Repeating steps 5-7, crimp the other half of the splice. 11. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt splice. c. Wire is visible through inspection hole of splices. 12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect battery ground cable. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10570 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10571 The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle harness. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 10572 C125 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Windshield Wiper Motor: Service and Repair Wiper Motor - Windshield WIPER MOTOR - WINDSHIELD Removal and Installation 1. Remove the front wiper pivot arms. 2. Remove the RH cowl grille panel. 3. Remove the LH cowl grille panel. 4. Disconnect the windshield wiper motor electrical connector. - Unclip the wiring harness from the wiper arm. - Position the wiring harness aside. 5. Remove the 3 windshield wiper assembly mounting bolts. - To install, tighten to 15 Nm (11 lb-ft). 6. Remove the windshield wiper assembly and position on a workbench. 7. Remove the windshield wiper motor mounting arm bolt and the wiper motor mounting arm. - To install, tighten to 15 Nm (11 lb-ft). 8. Remove the 3 windshield wiper motor mounting bolts. - To install, tighten to 15 Nm (11 lb-ft). 9. Remove the windshield wiper motor. 10. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Windshield > Page 10575 Wiper Motor: Service and Repair Wiper Motor - Rear Window WIPER MOTOR - REAR WINDOW Removal and Installation 1. Remove the rear wiper pivot arm. 2. Remove the rear window wiper motor grommet. 1 Remove the pivot shaft nut. To install, tighten to 10 Nm (89 lb-in). 2 Remove the grommet. 3. Open the liftgate window. 4. Remove the wiper motor cover trim panel. 5. Remove the rear window wiper motor. 1 Disconnect the electrical connectors. 2 Remove the 2 rear window wiper motor nuts. To install, tighten to 6 Nm (53 lb-in). 3 Remove the rear window wiper motor. 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 10579 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations View 151-10 (Instrument Panel) Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 10583 C202 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch, Wiper/Washer Portion Wiper Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch, Wiper/Washer Portion > Page 10586 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch, Wiper/Washer Portion > Page 10587 Ford Explorer 2wd Workshop Manual (V6-4.0L VIN K (2007)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 10588 Wiper Switch: Service and Repair Steering Column Multifunction Switch Steering Column Multifunction Switch Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column can result. 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the 2 screws and the steering column opening cover.