Factory Workshop Manual
Make
Ford
Model
Explorer 2wd
Engine and year
V8-4.6L (2008)
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This manual was submitted by
Anonymous
Date
1st January 2018
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory
Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8
Accessory Delay Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for
Communications Control Module: > 10-2-8 > Feb > 10 > SYNC(R) System - Defaults To 'Privacy Mode'
Communications Control Module: Customer Interest SYNC(R) System - Defaults To 'Privacy Mode'
TSB 10-2-8
02/15/10
SYNC SYSTEM DEFAULTS TO OR STAYS IN PRIVACY MODE, MULTIPLE VEHICLE LINES
FORD: 2008-2009 Taurus X 2008-2010 Focus, Fusion, Mustang, Taurus, Edge, Escape,
Expedition, Explorer Sport Trac, Explorer, F-150, F-250, F-350, F-450 2009-2010 Flex
LINCOLN: 2008-2010 MKZ 2009-2010 MKS 2008 Mark LT 2008-2010 MKX, Navigator 2010 MKT
MERCURY: 2008-2009 Sable 2008-2010 Milan, Mariner, Mountaineer
ISSUE Some customers of 2008-2010 SYNC-equipped vehicles may express concern with their
SYNC paired device defaulting, switching or staying on privacy mode. The customer may not be
able to accept the call through the SYNC system or must answer the call manually on their
personal device.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Set the Privacy mode to Off on the device and recheck Sync operation.
2. If necessary, test the device on another vehicle with the same version SYNC. If the concern is
still present, the device is the concern. Continue with
normal WSM Diagnostics.
NOTE
PRIVACY MODE MEANS THAT THE PHONE IS CONTROLLING THE AUDIO. SYNC ONLY
MAKES REQUESTS TO THE PHONE TO TRANSFER THIS RESPONSIBILITY OR AUDIO TO
SYNC. IF THE PHONE DOES NOT ACCEPT THIS REQUEST OR THERE IS A PROBLEM IN
THE COMMUNICATION TO MAKE THIS HAPPEN, YOU ARE BY DEFAULT IN PRIVACY MODE.
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for
Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns
Communications Control Module: Customer Interest SYNC(R) System - Software Update For
Various Concerns
TSB 09-26-8
01/04/10
SYNC SOFTWARE UPDATE - VARIOUS ISSUES
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009
Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner
This article supersedes TSB 9-22-14 to update the Service Procedure.
ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following
symptoms:
^ Universal Serial Bus (USB) port inoperative.
^ USB audio muting when using various non-Apple USB devices.
^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands.
^ Excessive background noise and/or poor voice sound quality.
^ Phone book auto download inoperative on supported devices.
^ SYNC steering wheel control (SWC) switches being inoperative intermittently.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace
processor (CIP) software levels.
^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report)
^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health
Report)
Service Pack files may be obtained at www.syncmyride.com.
Reprogram the APIM
Contains software fix updates for the following:
^ Phone book auto download inoperative.
^ USB audio muting.
^ SYNC steering wheel control (SWC) switches being inoperative.
^ Voice recognition on 2-digit entries.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for
Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns >
Page 21
^ USB port inoperative with diagnostic trouble code (DTC) B1342.
^ Poor call sound quality.
This software update also contains enhancements that will improve the reliability of both Bluetooth
and USB connections to SYNC(R) from various consumer devices, and microphone enhancements
to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The
Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple
call handling and other mobile phone features. The USB enhancements improve support for media
players and the playing of file formats and podcasts.
NOTE
REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC
SOFTWARE PROGRAMMING TIPS.
1. Connect the vehicle communication module (VCM) to the data link connector (DLC).
2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software.
3. Turn the ignition key to the on position.
4. Launch IDS tool.
5. If required, update the VCM with the latest software.
6. Close the IDS tool.
7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle
communication is established, press the GO button.
8. From the Vehicle Service Session screen, Select the SYNC button.
9. Press read APIM button.
10. Select software and press program APIM to update the SYNC module.
NOTE
YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER
CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP.
NOTE
DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING.
NOTE
THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW
THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY
INCLUDED IN WINDOWS XP.
11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP).
NOTE
DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE.
a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the
IDS tool or laptop running IDS software and
to the vehicle USB port.
b. Follow the on-screen instructions to program both processors on the Sync module (VIP and
CIP).
12. At the end of the configuration and programming procedure, the programming has been
completed successfully screen will be displayed.
13. Exit PTS, disconnect the VCM and disconnect the USB cable.
OTHER APPLICABLE ARTICLES: 08-21-02
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
092608A 2008-2009 Edge, Explorer, 0.4 Hr.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for
Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns >
Page 22
Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus,
Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty,
Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14D212 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for
Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set
Communications Control Module: Customer Interest SYNC(R) System - Functions
Inoperative/DTC's Set
TSB 09-14-3
07/27/09
SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY
DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED
FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge,
Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid,
Mariner
ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist
and Vehicle Health Report, may exhibit all or most of the following symptoms:
^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface
Module (APIM)
^ SYNC display menus/options blank
^ USB port inoperative
^ No SYNC Blue Tooth device connectivity
^ Voice/Phone/OK steering wheel controls inoperative
^ Lack of APIM communication
^ Parasitic battery draw with APIM connected
These symptoms may be triggered by a low battery state of charge, or a recent battery
disconnect/reconnect.
ACTION Follow the service procedure to correct the condition.
SERVICE PROCEDURE
This software upgrade only applies to the following Accessory Protocol Interface Module (APIM)
Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels:
^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC
^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD
^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD
To determine the current APIM software level, reference the Professional Technician Society (PTS)
website, enter the VIN in OASIS, click the GO
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for
Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 27
button and select the SYNC button.
1. Determine if communication can be established with the APIM using IDS.
a. If communication cannot be verified, proceed to Step 2.
b. If communication is present, proceed to Step 3.
2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if
communication can be established. If not, perform
an APIM power reset by disconnecting and reconnecting the vehicle battery.
a. If communication is now present, proceed to Step 3.
b. If communication still cannot be established, replace the APIM.
3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure.
NOTE
SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE
THROUGH THE SYNCMYRIDE.COM WEBSITE.
NOTE
CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS
APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID
AND PASSWORD.
a. Connect the vehicle communication module (VCM) to the data link connector (DLC).
b. Connect the VCM to the IDS tool or laptop running IDS software.
c. Turn the ignition key to the on position.
d. Launch IDS tool.
e. If required, update the VCM with the latest software.
f. Close the IDS tool.
g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle
communication is established, press the GO
button.
h. From the Vehicle Service Session screen, Select the SYNC button.
i. Press read APIM button.
j. Select software and press program APIM to update the SYNC module.
NOTE
YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER
CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP.
NOTE
DO NOT USE A TRANSFER TYPE CABLE.
NOTE
DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING.
NOTE
THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW
THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY
INCLUDED IN WINDOWS XP.
k. Program the processor in the APIM.
l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the
IDS tool or laptop running IDS software, and to the vehicle USB port.
m. Follow the on-screen instructions to program the VIP module.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for
Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 28
n. At the end of the configuration and programming procedure, the programming has been
completed successfully screen will be displayed.
o. Exit PTS, disconnect the VCM and disconnect the USB cable.
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
MT091403 Use SLTS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor Performed As Actual Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14D212 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Communications Control Module: > 10-2-8 > Feb > 10 > SYNC(R) System - Defaults To 'Privacy Mode'
Communications Control Module: All Technical Service Bulletins SYNC(R) System - Defaults To
'Privacy Mode'
TSB 10-2-8
02/15/10
SYNC SYSTEM DEFAULTS TO OR STAYS IN PRIVACY MODE, MULTIPLE VEHICLE LINES
FORD: 2008-2009 Taurus X 2008-2010 Focus, Fusion, Mustang, Taurus, Edge, Escape,
Expedition, Explorer Sport Trac, Explorer, F-150, F-250, F-350, F-450 2009-2010 Flex
LINCOLN: 2008-2010 MKZ 2009-2010 MKS 2008 Mark LT 2008-2010 MKX, Navigator 2010 MKT
MERCURY: 2008-2009 Sable 2008-2010 Milan, Mariner, Mountaineer
ISSUE Some customers of 2008-2010 SYNC-equipped vehicles may express concern with their
SYNC paired device defaulting, switching or staying on privacy mode. The customer may not be
able to accept the call through the SYNC system or must answer the call manually on their
personal device.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Set the Privacy mode to Off on the device and recheck Sync operation.
2. If necessary, test the device on another vehicle with the same version SYNC. If the concern is
still present, the device is the concern. Continue with
normal WSM Diagnostics.
NOTE
PRIVACY MODE MEANS THAT THE PHONE IS CONTROLLING THE AUDIO. SYNC ONLY
MAKES REQUESTS TO THE PHONE TO TRANSFER THIS RESPONSIBILITY OR AUDIO TO
SYNC. IF THE PHONE DOES NOT ACCEPT THIS REQUEST OR THERE IS A PROBLEM IN
THE COMMUNICATION TO MAKE THIS HAPPEN, YOU ARE BY DEFAULT IN PRIVACY MODE.
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns
Communications Control Module: All Technical Service Bulletins SYNC(R) System - Software
Update For Various Concerns
TSB 09-26-8
01/04/10
SYNC SOFTWARE UPDATE - VARIOUS ISSUES
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009
Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner
This article supersedes TSB 9-22-14 to update the Service Procedure.
ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following
symptoms:
^ Universal Serial Bus (USB) port inoperative.
^ USB audio muting when using various non-Apple USB devices.
^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands.
^ Excessive background noise and/or poor voice sound quality.
^ Phone book auto download inoperative on supported devices.
^ SYNC steering wheel control (SWC) switches being inoperative intermittently.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace
processor (CIP) software levels.
^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report)
^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health
Report)
Service Pack files may be obtained at www.syncmyride.com.
Reprogram the APIM
Contains software fix updates for the following:
^ Phone book auto download inoperative.
^ USB audio muting.
^ SYNC steering wheel control (SWC) switches being inoperative.
^ Voice recognition on 2-digit entries.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns >
Page 38
^ USB port inoperative with diagnostic trouble code (DTC) B1342.
^ Poor call sound quality.
This software update also contains enhancements that will improve the reliability of both Bluetooth
and USB connections to SYNC(R) from various consumer devices, and microphone enhancements
to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The
Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple
call handling and other mobile phone features. The USB enhancements improve support for media
players and the playing of file formats and podcasts.
NOTE
REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC
SOFTWARE PROGRAMMING TIPS.
1. Connect the vehicle communication module (VCM) to the data link connector (DLC).
2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software.
3. Turn the ignition key to the on position.
4. Launch IDS tool.
5. If required, update the VCM with the latest software.
6. Close the IDS tool.
7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle
communication is established, press the GO button.
8. From the Vehicle Service Session screen, Select the SYNC button.
9. Press read APIM button.
10. Select software and press program APIM to update the SYNC module.
NOTE
YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER
CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP.
NOTE
DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING.
NOTE
THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW
THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY
INCLUDED IN WINDOWS XP.
11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP).
NOTE
DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE.
a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the
IDS tool or laptop running IDS software and
to the vehicle USB port.
b. Follow the on-screen instructions to program both processors on the Sync module (VIP and
CIP).
12. At the end of the configuration and programming procedure, the programming has been
completed successfully screen will be displayed.
13. Exit PTS, disconnect the VCM and disconnect the USB cable.
OTHER APPLICABLE ARTICLES: 08-21-02
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
092608A 2008-2009 Edge, Explorer, 0.4 Hr.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns >
Page 39
Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus,
Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty,
Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14D212 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set
Communications Control Module: All Technical Service Bulletins SYNC(R) System - Functions
Inoperative/DTC's Set
TSB 09-14-3
07/27/09
SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY
DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED
FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge,
Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid,
Mariner
ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist
and Vehicle Health Report, may exhibit all or most of the following symptoms:
^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface
Module (APIM)
^ SYNC display menus/options blank
^ USB port inoperative
^ No SYNC Blue Tooth device connectivity
^ Voice/Phone/OK steering wheel controls inoperative
^ Lack of APIM communication
^ Parasitic battery draw with APIM connected
These symptoms may be triggered by a low battery state of charge, or a recent battery
disconnect/reconnect.
ACTION Follow the service procedure to correct the condition.
SERVICE PROCEDURE
This software upgrade only applies to the following Accessory Protocol Interface Module (APIM)
Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels:
^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC
^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD
^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD
To determine the current APIM software level, reference the Professional Technician Society (PTS)
website, enter the VIN in OASIS, click the GO
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 44
button and select the SYNC button.
1. Determine if communication can be established with the APIM using IDS.
a. If communication cannot be verified, proceed to Step 2.
b. If communication is present, proceed to Step 3.
2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if
communication can be established. If not, perform
an APIM power reset by disconnecting and reconnecting the vehicle battery.
a. If communication is now present, proceed to Step 3.
b. If communication still cannot be established, replace the APIM.
3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure.
NOTE
SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE
THROUGH THE SYNCMYRIDE.COM WEBSITE.
NOTE
CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS
APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID
AND PASSWORD.
a. Connect the vehicle communication module (VCM) to the data link connector (DLC).
b. Connect the VCM to the IDS tool or laptop running IDS software.
c. Turn the ignition key to the on position.
d. Launch IDS tool.
e. If required, update the VCM with the latest software.
f. Close the IDS tool.
g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle
communication is established, press the GO
button.
h. From the Vehicle Service Session screen, Select the SYNC button.
i. Press read APIM button.
j. Select software and press program APIM to update the SYNC module.
NOTE
YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER
CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP.
NOTE
DO NOT USE A TRANSFER TYPE CABLE.
NOTE
DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING.
NOTE
THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW
THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY
INCLUDED IN WINDOWS XP.
k. Program the processor in the APIM.
l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the
IDS tool or laptop running IDS software, and to the vehicle USB port.
m. Follow the on-screen instructions to program the VIP module.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 45
n. At the end of the configuration and programming procedure, the programming has been
completed successfully screen will be displayed.
o. Exit PTS, disconnect the VCM and disconnect the USB cable.
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
MT091403 Use SLTS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor Performed As Actual Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14D212 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Locations > Audio Control Module
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM)
Communications Control Module: Diagrams Accessory Protocol Interface Module (APIM)
C3342 (Part 1)
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Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) >
Page 51
C3342 (Part 2)
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Page 52
Communications Control Module: Diagrams Audio Control Module
C290A
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Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) >
Page 53
C290B
C290C
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Communications Control Module > Component Information > Diagrams > Page 54
Communications Control Module: Service and Repair
AUDIO CONTROL MODULE (ACM)
Removal and Installation
NOTE:
- When installing a new navigation audio control module (ACM), remove the navigation DVD before
sending the ACM to an authorized audio system repair facility.
- It is not necessary to remove the ACM to retrieve the part number.
1. NOTE: Module configuration is only required if a new ACM is being installed.
Upload the ACM configuration information to the scan tool. Refer to Information Bus (Module
Configuration) to carry out programmable module installation (PMI). See: Powertrain
Management/Computers and Control Systems/Information Bus/Testing and
Inspection/Programming and Relearning
2. Remove the instrument panel center finish panel. 3. Remove the 4 screws and the ACM.
- Disconnect the ACM electrical connectors and the antenna lead-in cable(s).
4. To install, reverse the removal procedure.
- Download the configuration information to the ACM.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency
Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 >
SYNC(R) System - Functions Inoperative/DTC's Set
Emergency Contact Module: Customer Interest SYNC(R) System - Functions Inoperative/DTC's
Set
TSB 09-14-3
07/27/09
SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY
DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED
FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge,
Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid,
Mariner
ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist
and Vehicle Health Report, may exhibit all or most of the following symptoms:
^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface
Module (APIM)
^ SYNC display menus/options blank
^ USB port inoperative
^ No SYNC Blue Tooth device connectivity
^ Voice/Phone/OK steering wheel controls inoperative
^ Lack of APIM communication
^ Parasitic battery draw with APIM connected
These symptoms may be triggered by a low battery state of charge, or a recent battery
disconnect/reconnect.
ACTION Follow the service procedure to correct the condition.
SERVICE PROCEDURE
This software upgrade only applies to the following Accessory Protocol Interface Module (APIM)
Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels:
^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC
^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD
^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD
To determine the current APIM software level, reference the Professional Technician Society (PTS)
website, enter the VIN in OASIS, click the GO
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SYNC(R) System - Functions Inoperative/DTC's Set > Page 63
button and select the SYNC button.
1. Determine if communication can be established with the APIM using IDS.
a. If communication cannot be verified, proceed to Step 2.
b. If communication is present, proceed to Step 3.
2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if
communication can be established. If not, perform
an APIM power reset by disconnecting and reconnecting the vehicle battery.
a. If communication is now present, proceed to Step 3.
b. If communication still cannot be established, replace the APIM.
3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure.
NOTE
SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE
THROUGH THE SYNCMYRIDE.COM WEBSITE.
NOTE
CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS
APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID
AND PASSWORD.
a. Connect the vehicle communication module (VCM) to the data link connector (DLC).
b. Connect the VCM to the IDS tool or laptop running IDS software.
c. Turn the ignition key to the on position.
d. Launch IDS tool.
e. If required, update the VCM with the latest software.
f. Close the IDS tool.
g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle
communication is established, press the GO
button.
h. From the Vehicle Service Session screen, Select the SYNC button.
i. Press read APIM button.
j. Select software and press program APIM to update the SYNC module.
NOTE
YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER
CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP.
NOTE
DO NOT USE A TRANSFER TYPE CABLE.
NOTE
DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING.
NOTE
THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW
THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY
INCLUDED IN WINDOWS XP.
k. Program the processor in the APIM.
l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the
IDS tool or laptop running IDS software, and to the vehicle USB port.
m. Follow the on-screen instructions to program the VIP module.
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Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 >
SYNC(R) System - Functions Inoperative/DTC's Set > Page 64
n. At the end of the configuration and programming procedure, the programming has been
completed successfully screen will be displayed.
o. Exit PTS, disconnect the VCM and disconnect the USB cable.
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
MT091403 Use SLTS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor Performed As Actual Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14D212 04
Disclaimer
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency
Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality
Emergency Contact Module: Customer Interest SYNC(R) System - Poor Cell Phone Sound Quality
TSB 09-13-5
07/13/09
SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE
RECOGNITION DIFFICULTIES WHILE DRIVING
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009
Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner
ISSUE Some customers of 2008-2009 SYNC equipped vehicles may express concern with their
call sound quality while using the SYNC microphone, complaints of excessive background noise
during a phone call, and/or issues with voice recognition accuracy while driving.
ACTION Follow the service procedure to correct the condition.
SERVICE PROCEDURE
The following service procedure involves updating the Accessory Protocol Interface Module (APIM)
software level and installing an external alternate SYNC microphone attached to the headliner.
NOTE
THIS PROCEDURE DOES NOT APPLY TO DEALER-INSTALLED SYNC SYSTEMS.
Do not perform Step 1 if vehicle is already equipped with SYNC 2.0 (911 and Vehicle Health
Report) or has been upgraded to consumer interface processor (CIP) level 9L3T-14D544-AE. To
determine the current APIM software level, Refer to the Professional Technician Society (PTS)
website, enter the VIN in OASIS, click the GO button, and select the SYNC button.
1. Reprogram the APIM to CIP software level 9L3T-14D544-AE. For additional information Refer to
other SYNC TSB's and WSM, Section 418-01.
Service Pack files may also be obtained at www.syncmyride.com.
When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to
test VR functionality while the vehicle is parked. If customer concerns are still present, this
procedure will not yield an improvement, and the service procedure should not be performed.
Instead, Refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to
assist customer.
The VR experience can be improved with user training and making improvements to the phone
book entries (longer entries make the system more robust). Ensure the customer does not try to
speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce
system effectiveness.
When diagnosing a concern related to call sound quality, expect marginal improvements for calls
described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints
where the call audio seems to drop out intermittently.
NOTE
THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO
THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO
NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING
WITH MICROPHONE INSTALLATION.
2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone
directly to the headliner and splicing in a jumper
harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be
functional.
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Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 69
a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone
installation and wire splicing locations. Refer to
Wiring Diagram (WD), Section 5-1 for recommended splicing methods.
b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or
functionality.
c. The microphone is directional. Make sure the microphone is always positioned so wire length is
minimized from view. When installing the
microphone adjacent to trim, place microphone as close to trim as possible to help minimize visible
wire.
2008-2009 Edge / MKX
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 1)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable up through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124-1 for
links to location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C211. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C210.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
cut wire ends heading up the A-pillar as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2009 Escape / Mariner
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Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 70
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration (Figures 2 and 3). Firmly
press the microphone into place. Ensure the microphone is parallel and adjacent to overhead
console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an
overhead console. Proceed to Step 5 if not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 501-05 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner to
run microphone cable.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C214. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP41 (BU) and GD182 (BK-GY) from C214.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD1 82 (BK-GY).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
cut wire ends heading up the A-pillar as they are no longer used.
9. Connect the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2008-2009 Navigator / 2009 Expedition
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Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 71
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figures 4 and 5)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or
positioned directly above A-pillar on headliner if not
equipped with an overhead console.
^ Proceed to Step 5 if not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online
WD, Section 124-1 for links to location and connector
views.
6. Identify circuits VMN07 (GY), RMN07 (VT), and DMN07 (shield - BK) from C298. Cut the three
circuits on the male side of the connector
(17C712 harness).
7. Identify circuits CBP31 (BU-OG) and GD133 (BK) from C298 (2008 Navigator only). Identify
circuits CBP41 (BU) and GD133 (BK) from C298
(2009 Expedition/Navigator only).
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP31 (BU-OG) and any black jumper harness wire to GD133 (BK)
for 2008 Navigator only. Blue jumper harness wire to CBP41 (BU) and any black jumper harness
wire to GD133 (BK) for 2009 Expedition/Navigator only.
^ Ensure original circuits remain connected in splice.
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Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 72
^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07
(VT) and DMN07 (shield - BK).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Connect the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the headliner.
2008-2009 Explorer / Explorer Sport Trac / Mountaineer
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 6)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner run
microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify and cut circuits VMNO7 (GY), RMNO7 (VT), and DMNO7 (shield) from C248. Cut the
three circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP05 (YE) and GD143 (BK-VT) from C248.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP05 (YE) and any black jumper harness wire to GD143 (BK-VT).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07
(VT) and DMN07 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
cut wire ends heading up the A-pillar as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2009 F-150
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Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 73
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 7)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp.
2. Lower the overhead console or front lamp. Refer to WSM, Section 417-02 for additional
information.
3. Route microphone cable through existing hole in the headliner, and temporarily tuck excess wire
into headliner to the rear of the console or lamp.
4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or
front lamp trim directly behind microphone as
shown.
5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD,
Section 124-1 for links to location and connector
views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C314. Cut the three
circuits on the female side of the connector
(14358 harness).
7. Identify circuits CBP41 (BU) from C315 and GD133 (BK) from C314.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the headliner.
2009 F-Super Duty
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SYNC(R) System - Poor Cell Phone Sound Quality > Page 74
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 8)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
c. This repair is not recommended for vehicles not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield - BK) from C264. Cut the
three circuits on the female side of the connector
(17K745 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C264.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield - BK).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Connect the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2009 Flex
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Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 75
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 9)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C925. Cut the three
circuits on the female side of the connector (14334 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C925.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2008-2009 Focus
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SYNC(R) System - Poor Cell Phone Sound Quality > Page 76
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration (Figure 10). Firmly press
the microphone into place. Ensure the microphone is parallel and adjacent to the dome lamp trim.
2. Lower the dome lamp assembly. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable up through existing hole in the headliner, and over to the passenger
side A-pillar. It may be necessary to slightly drop
headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install dome lamp assembly; ensure microphone cable enters the dome lamp trim directly behind
microphone as shown.
5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector
views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C934. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CPL60 (BN-YE) and GD161 (BK-YE) from C934.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CPL60 (BN-YE) and any black jumper harness wire to GD161
(BK-YE).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2008-2009 Fusion / Milan / MKZ
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 77
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 11)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C913. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP02 (GN) and GD139 (BK-YE) from C913.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP02 (GN) and any black jumper harness wire to GD139 (BK-YE).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2008-2009 Taurus / Sable / Taurus X
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 12)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner to
run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
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Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 78
5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMN02 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C925. Cut the
three circuits on the female side of the connector
(17K745 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C925.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to
RMN02 (VT-BN) and DMN07 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2009 MKS
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 13)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and out the front of the headliner
above the rear view mirror.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124-1 for
links to location and connector views.
6. Identify circuits VMNO2 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C911. Pull back
the black harness sleeve and cut the three
circuits near C91 1 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2
access cover and cut circuits under trim cover. Refer to WSM, Section 417-01 for additional
information.
7. Identify circuits CBP41 (BU) and GD133 (BK) from C911.
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Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 79
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to
RMN02 (VT-BN) and DMN07 (shield).
^ Only splice into the wires heading away from the connector. The wires heading into the connector
(mirror) are no longer used.
^ Ensure the wiring is neatly routed from the splice locations into the headliner, following the
existing wire harness routing from mirror to headliner.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
OTHER APPLICABLE ARTICLES: 08-21-2
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
MT091305 Claim Diagnosis And Labor Actual
Performed As Actual Time. Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
17700 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency
Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency
Contact Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set
Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - Functions
Inoperative/DTC's Set
TSB 09-14-3
07/27/09
SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY
DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED
FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge,
Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid,
Mariner
ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist
and Vehicle Health Report, may exhibit all or most of the following symptoms:
^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface
Module (APIM)
^ SYNC display menus/options blank
^ USB port inoperative
^ No SYNC Blue Tooth device connectivity
^ Voice/Phone/OK steering wheel controls inoperative
^ Lack of APIM communication
^ Parasitic battery draw with APIM connected
These symptoms may be triggered by a low battery state of charge, or a recent battery
disconnect/reconnect.
ACTION Follow the service procedure to correct the condition.
SERVICE PROCEDURE
This software upgrade only applies to the following Accessory Protocol Interface Module (APIM)
Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels:
^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC
^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD
^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD
To determine the current APIM software level, reference the Professional Technician Society (PTS)
website, enter the VIN in OASIS, click the GO
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Contact Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 85
button and select the SYNC button.
1. Determine if communication can be established with the APIM using IDS.
a. If communication cannot be verified, proceed to Step 2.
b. If communication is present, proceed to Step 3.
2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if
communication can be established. If not, perform
an APIM power reset by disconnecting and reconnecting the vehicle battery.
a. If communication is now present, proceed to Step 3.
b. If communication still cannot be established, replace the APIM.
3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure.
NOTE
SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE
THROUGH THE SYNCMYRIDE.COM WEBSITE.
NOTE
CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS
APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID
AND PASSWORD.
a. Connect the vehicle communication module (VCM) to the data link connector (DLC).
b. Connect the VCM to the IDS tool or laptop running IDS software.
c. Turn the ignition key to the on position.
d. Launch IDS tool.
e. If required, update the VCM with the latest software.
f. Close the IDS tool.
g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle
communication is established, press the GO
button.
h. From the Vehicle Service Session screen, Select the SYNC button.
i. Press read APIM button.
j. Select software and press program APIM to update the SYNC module.
NOTE
YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER
CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP.
NOTE
DO NOT USE A TRANSFER TYPE CABLE.
NOTE
DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING.
NOTE
THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW
THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY
INCLUDED IN WINDOWS XP.
k. Program the processor in the APIM.
l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the
IDS tool or laptop running IDS software, and to the vehicle USB port.
m. Follow the on-screen instructions to program the VIP module.
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Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency
Contact Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 86
n. At the end of the configuration and programming procedure, the programming has been
completed successfully screen will be displayed.
o. Exit PTS, disconnect the VCM and disconnect the USB cable.
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
MT091403 Use SLTS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor Performed As Actual Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14D212 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency
Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency
Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality
Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - Poor Cell Phone
Sound Quality
TSB 09-13-5
07/13/09
SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE
RECOGNITION DIFFICULTIES WHILE DRIVING
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009
Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner
ISSUE Some customers of 2008-2009 SYNC equipped vehicles may express concern with their
call sound quality while using the SYNC microphone, complaints of excessive background noise
during a phone call, and/or issues with voice recognition accuracy while driving.
ACTION Follow the service procedure to correct the condition.
SERVICE PROCEDURE
The following service procedure involves updating the Accessory Protocol Interface Module (APIM)
software level and installing an external alternate SYNC microphone attached to the headliner.
NOTE
THIS PROCEDURE DOES NOT APPLY TO DEALER-INSTALLED SYNC SYSTEMS.
Do not perform Step 1 if vehicle is already equipped with SYNC 2.0 (911 and Vehicle Health
Report) or has been upgraded to consumer interface processor (CIP) level 9L3T-14D544-AE. To
determine the current APIM software level, Refer to the Professional Technician Society (PTS)
website, enter the VIN in OASIS, click the GO button, and select the SYNC button.
1. Reprogram the APIM to CIP software level 9L3T-14D544-AE. For additional information Refer to
other SYNC TSB's and WSM, Section 418-01.
Service Pack files may also be obtained at www.syncmyride.com.
When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to
test VR functionality while the vehicle is parked. If customer concerns are still present, this
procedure will not yield an improvement, and the service procedure should not be performed.
Instead, Refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to
assist customer.
The VR experience can be improved with user training and making improvements to the phone
book entries (longer entries make the system more robust). Ensure the customer does not try to
speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce
system effectiveness.
When diagnosing a concern related to call sound quality, expect marginal improvements for calls
described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints
where the call audio seems to drop out intermittently.
NOTE
THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO
THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO
NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING
WITH MICROPHONE INSTALLATION.
2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone
directly to the headliner and splicing in a jumper
harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be
functional.
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Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 91
a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone
installation and wire splicing locations. Refer to
Wiring Diagram (WD), Section 5-1 for recommended splicing methods.
b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or
functionality.
c. The microphone is directional. Make sure the microphone is always positioned so wire length is
minimized from view. When installing the
microphone adjacent to trim, place microphone as close to trim as possible to help minimize visible
wire.
2008-2009 Edge / MKX
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 1)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable up through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124-1 for
links to location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C211. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C210.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
cut wire ends heading up the A-pillar as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2009 Escape / Mariner
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Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency
Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 92
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration (Figures 2 and 3). Firmly
press the microphone into place. Ensure the microphone is parallel and adjacent to overhead
console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an
overhead console. Proceed to Step 5 if not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 501-05 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner to
run microphone cable.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C214. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP41 (BU) and GD182 (BK-GY) from C214.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD1 82 (BK-GY).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
cut wire ends heading up the A-pillar as they are no longer used.
9. Connect the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2008-2009 Navigator / 2009 Expedition
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Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency
Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 93
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figures 4 and 5)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or
positioned directly above A-pillar on headliner if not
equipped with an overhead console.
^ Proceed to Step 5 if not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online
WD, Section 124-1 for links to location and connector
views.
6. Identify circuits VMN07 (GY), RMN07 (VT), and DMN07 (shield - BK) from C298. Cut the three
circuits on the male side of the connector
(17C712 harness).
7. Identify circuits CBP31 (BU-OG) and GD133 (BK) from C298 (2008 Navigator only). Identify
circuits CBP41 (BU) and GD133 (BK) from C298
(2009 Expedition/Navigator only).
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP31 (BU-OG) and any black jumper harness wire to GD133 (BK)
for 2008 Navigator only. Blue jumper harness wire to CBP41 (BU) and any black jumper harness
wire to GD133 (BK) for 2009 Expedition/Navigator only.
^ Ensure original circuits remain connected in splice.
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Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 94
^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07
(VT) and DMN07 (shield - BK).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Connect the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the headliner.
2008-2009 Explorer / Explorer Sport Trac / Mountaineer
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 6)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner run
microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify and cut circuits VMNO7 (GY), RMNO7 (VT), and DMNO7 (shield) from C248. Cut the
three circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP05 (YE) and GD143 (BK-VT) from C248.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP05 (YE) and any black jumper harness wire to GD143 (BK-VT).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07
(VT) and DMN07 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
cut wire ends heading up the A-pillar as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2009 F-150
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Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 95
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 7)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp.
2. Lower the overhead console or front lamp. Refer to WSM, Section 417-02 for additional
information.
3. Route microphone cable through existing hole in the headliner, and temporarily tuck excess wire
into headliner to the rear of the console or lamp.
4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or
front lamp trim directly behind microphone as
shown.
5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD,
Section 124-1 for links to location and connector
views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C314. Cut the three
circuits on the female side of the connector
(14358 harness).
7. Identify circuits CBP41 (BU) from C315 and GD133 (BK) from C314.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the headliner.
2009 F-Super Duty
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Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 96
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 8)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
c. This repair is not recommended for vehicles not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield - BK) from C264. Cut the
three circuits on the female side of the connector
(17K745 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C264.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield - BK).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Connect the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2009 Flex
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Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 97
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 9)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C925. Cut the three
circuits on the female side of the connector (14334 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C925.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2008-2009 Focus
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency
Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency
Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 98
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration (Figure 10). Firmly press
the microphone into place. Ensure the microphone is parallel and adjacent to the dome lamp trim.
2. Lower the dome lamp assembly. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable up through existing hole in the headliner, and over to the passenger
side A-pillar. It may be necessary to slightly drop
headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install dome lamp assembly; ensure microphone cable enters the dome lamp trim directly behind
microphone as shown.
5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector
views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C934. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CPL60 (BN-YE) and GD161 (BK-YE) from C934.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CPL60 (BN-YE) and any black jumper harness wire to GD161
(BK-YE).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2008-2009 Fusion / Milan / MKZ
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency
Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency
Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 99
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 11)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C913. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP02 (GN) and GD139 (BK-YE) from C913.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP02 (GN) and any black jumper harness wire to GD139 (BK-YE).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2008-2009 Taurus / Sable / Taurus X
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 12)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner to
run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency
Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency
Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 100
5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMN02 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C925. Cut the
three circuits on the female side of the connector
(17K745 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C925.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to
RMN02 (VT-BN) and DMN07 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2009 MKS
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 13)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and out the front of the headliner
above the rear view mirror.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124-1 for
links to location and connector views.
6. Identify circuits VMNO2 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C911. Pull back
the black harness sleeve and cut the three
circuits near C91 1 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2
access cover and cut circuits under trim cover. Refer to WSM, Section 417-01 for additional
information.
7. Identify circuits CBP41 (BU) and GD133 (BK) from C911.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency
Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency
Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 101
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to
RMN02 (VT-BN) and DMN07 (shield).
^ Only splice into the wires heading away from the connector. The wires heading into the connector
(mirror) are no longer used.
^ Ensure the wiring is neatly routed from the splice locations into the headliner, following the
existing wire harness routing from mirror to headliner.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
OTHER APPLICABLE ARTICLES: 08-21-2
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
MT091305 Claim Diagnosis And Labor Actual
Performed As Actual Time. Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
17700 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency
Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency
Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade
Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - 911 Assist VHR
Software Upgrade
TSB 09-11-8
06/15/09
SYNC WITH 911 ASSIST AND VEHICLE HEALTH REPORT (VHR) DEALER UPGRADE
SOFTWARE
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009
Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner
This article supersedes TSB 9-5-4 to update the Service Procedure and add a production fix date.
ISSUE Some customers with 2008 or 2009 vehicles equipped with SYNC may request the 911
assist and vehicle health report (VHR) service upgrade installation. This software upgrade is not a
warrantable repair. Software is available only through professional technician society (PTS)
website, and not available through the syncmyride.com website.
ACTION Follow the Service Procedure steps to upgrade the SYNC software.
SERVICE PROCEDURE
This software upgrade applies only to the following vehicle model years and build dates:
^ 2008-2009 Focus built before 1/20/2009
^ 2008-2009 Explorer, Explorer Sport Trac, Mountaineer built before 1/12/2009
^ 2008-2009 Edge, MKX, and 2009 Flex, Escape, Mariner built before 12/4/2008
^ 2008-2009 Taurus, Taurus X, Sable, and 2009 F-Super Duty, MKS, F-150 built before 12/1/2008
^ 2008-2009 Fusion, Milan, MKZ
Vehicles built on or after these dates are already equipped with the 911 Assist/Vehicle Health
Report features and do not require updating.
To determine if the vehicles are within these build ranges or have already been upgraded to SYNC
911 Assist/VHR, access the Professional Technician Society (PTS) website, run OASIS by
pressing the Read VIN and DTC's button, and click on the SYNC tab. If the description box
indicates 911 and Vehicle Health Report, vehicle has been upgraded.
The 911 assist with VHR upgrade automatically reprograms the accessory protocol interface
module (APIM), instrument cluster (IC), and restraints control module (RCM).
The VHR applies only to United States (US) vehicles, 911 assist is for US and Canadian vehicles
operated within the US and Canada.
Performing this upgrade may result in some untested devices losing certain functionality, such as
bluetooth connection and phonebook download. Before continuing with this upgrade, make sure
the customer's device is listed on the compatibility matrix. It is strongly recommended to pair the
device to another vehicle currently equipped with 911 Assist/Vehicle Health Report to ensure
proper functionality before continuing.
Configuration and programming requires the use of IDS and a special PTS application. Installer
must have access to PTS and have a valid PTS user ID and password. Ensure the IDS is at the
latest software version.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency
Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency
Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 106
For additional programming tips, dealer network setting requirements, and possible error states
related to 911 Assist and VHR upgrades, reference the latest information on the Professional
Technician Society (PTS) website.
1. When updating 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator
vehicles, it is necessary to manually record and
reenter the Oil Life % Value as displayed on the message center. Record the current oil life before
updating 911 Assist/VHR, and reenter using the message center once programming is complete.
2. Connect the vehicle communication module (VCM) to the data link connector (DLC).
3. Connect the VCM to the IDS tool or laptop running IDS software.
4. Turn the ignition key to the on position.
5. Launch IDS tool but do not start a new session.
6. If required, update the VCM with the latest IDS release 59.9 and higher.
7. Close the IDS tool.
8. From the P15 website, run OASIS by pressing the read VIN and DTC's button. After vehicle
communication is established, press the go button.
9. From the Vehicle Service Session screen, select the Upgrade/Mods tab.
10. Once correct vehicle is chosen, select SYNC upgrade with 911 Assist/VHR.
11. Follow the on-screen instructions to program the APIM, IC, and RCM.
NOTE
TO COMPLETE THE UPGRADE PROCESS PERFORM THE FOLLOWING STEPS TO CONFIRM
THE VEHICLE HAS BEEN CORRECTLY CONFIGURED TO HAVE THESE FEATURES. FAILING
TO COMPLETE THE STEPS BELOW MAY RESULT IN 911 ASSIST/VHR NOT DISPLAYING ON
THE SYNC MENU.
12. Set ignition to off.
13. Open and close driver side door.
14. Set ignition to on.
15. Follow applicable instructions (see below) to ensure 911 Assist/VHR appear on Sync menu.
16. Close all Internet Explorer browser windows.
17. Clear all DTC's on all modules.
18. Reenter the Oil Life % Value for 2008-2009 Explorer, Mountaineer, Explorer Sport Trac,
Expedition, or Navigator vehicles.
Navigation Radio Instructions
911 Assist/VHR feature confirmation.
1. Press phone button on the Navigation LCD to enter phone menu.
2. Press cancel when pop-up menu appears on Navigation LCD display.
3. Press settings soft key on Navigation LCD display.
4. Press advanced soft key on Navigation LCD display.
5. Verify 911 Assist/VHR is in menu in Navigation LCD display.
Non Navigation Radio Instructions
911 Assist/VHR feature confirmation.
1. Press phone button on steering wheel.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency
Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency
Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 107
2. Press left arrow on steering wheel until return is displayed on radio screen, then press ok.
3. Press left arrow on steering wheel until return is displayed on radio screen, then press ok.
4. Press left arrow until 911 Assist/VHR is displayed.
Once 911 Assist/VHR installation is complete, the customer will need to reload their phone book if
that application is desired.
NOTE
IF SERVICE IS REQUIRED ON 2008 OR 2009 EARLY BUILT VEHICLES UPGRADED TO 911
ASSIST/VHR, REFERENCE THE APPLICABLE 2009 WORKSHOP MANUAL AND FOLLOW THE
V2 DIAGNOSTIC PROCEDURES.
WARRANTY STATUS: Information Only - Not Warrantable
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency
Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact
Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade
Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - 911 Assist VHR
Software Upgrade
TSB 09-11-8
06/15/09
SYNC WITH 911 ASSIST AND VEHICLE HEALTH REPORT (VHR) DEALER UPGRADE
SOFTWARE
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009
Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner
This article supersedes TSB 9-5-4 to update the Service Procedure and add a production fix date.
ISSUE Some customers with 2008 or 2009 vehicles equipped with SYNC may request the 911
assist and vehicle health report (VHR) service upgrade installation. This software upgrade is not a
warrantable repair. Software is available only through professional technician society (PTS)
website, and not available through the syncmyride.com website.
ACTION Follow the Service Procedure steps to upgrade the SYNC software.
SERVICE PROCEDURE
This software upgrade applies only to the following vehicle model years and build dates:
^ 2008-2009 Focus built before 1/20/2009
^ 2008-2009 Explorer, Explorer Sport Trac, Mountaineer built before 1/12/2009
^ 2008-2009 Edge, MKX, and 2009 Flex, Escape, Mariner built before 12/4/2008
^ 2008-2009 Taurus, Taurus X, Sable, and 2009 F-Super Duty, MKS, F-150 built before 12/1/2008
^ 2008-2009 Fusion, Milan, MKZ
Vehicles built on or after these dates are already equipped with the 911 Assist/Vehicle Health
Report features and do not require updating.
To determine if the vehicles are within these build ranges or have already been upgraded to SYNC
911 Assist/VHR, access the Professional Technician Society (PTS) website, run OASIS by
pressing the Read VIN and DTC's button, and click on the SYNC tab. If the description box
indicates 911 and Vehicle Health Report, vehicle has been upgraded.
The 911 assist with VHR upgrade automatically reprograms the accessory protocol interface
module (APIM), instrument cluster (IC), and restraints control module (RCM).
The VHR applies only to United States (US) vehicles, 911 assist is for US and Canadian vehicles
operated within the US and Canada.
Performing this upgrade may result in some untested devices losing certain functionality, such as
bluetooth connection and phonebook download. Before continuing with this upgrade, make sure
the customer's device is listed on the compatibility matrix. It is strongly recommended to pair the
device to another vehicle currently equipped with 911 Assist/Vehicle Health Report to ensure
proper functionality before continuing.
Configuration and programming requires the use of IDS and a special PTS application. Installer
must have access to PTS and have a valid PTS user ID and password. Ensure the IDS is at the
latest software version.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency
Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact
Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 113
For additional programming tips, dealer network setting requirements, and possible error states
related to 911 Assist and VHR upgrades, reference the latest information on the Professional
Technician Society (PTS) website.
1. When updating 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator
vehicles, it is necessary to manually record and
reenter the Oil Life % Value as displayed on the message center. Record the current oil life before
updating 911 Assist/VHR, and reenter using the message center once programming is complete.
2. Connect the vehicle communication module (VCM) to the data link connector (DLC).
3. Connect the VCM to the IDS tool or laptop running IDS software.
4. Turn the ignition key to the on position.
5. Launch IDS tool but do not start a new session.
6. If required, update the VCM with the latest IDS release 59.9 and higher.
7. Close the IDS tool.
8. From the P15 website, run OASIS by pressing the read VIN and DTC's button. After vehicle
communication is established, press the go button.
9. From the Vehicle Service Session screen, select the Upgrade/Mods tab.
10. Once correct vehicle is chosen, select SYNC upgrade with 911 Assist/VHR.
11. Follow the on-screen instructions to program the APIM, IC, and RCM.
NOTE
TO COMPLETE THE UPGRADE PROCESS PERFORM THE FOLLOWING STEPS TO CONFIRM
THE VEHICLE HAS BEEN CORRECTLY CONFIGURED TO HAVE THESE FEATURES. FAILING
TO COMPLETE THE STEPS BELOW MAY RESULT IN 911 ASSIST/VHR NOT DISPLAYING ON
THE SYNC MENU.
12. Set ignition to off.
13. Open and close driver side door.
14. Set ignition to on.
15. Follow applicable instructions (see below) to ensure 911 Assist/VHR appear on Sync menu.
16. Close all Internet Explorer browser windows.
17. Clear all DTC's on all modules.
18. Reenter the Oil Life % Value for 2008-2009 Explorer, Mountaineer, Explorer Sport Trac,
Expedition, or Navigator vehicles.
Navigation Radio Instructions
911 Assist/VHR feature confirmation.
1. Press phone button on the Navigation LCD to enter phone menu.
2. Press cancel when pop-up menu appears on Navigation LCD display.
3. Press settings soft key on Navigation LCD display.
4. Press advanced soft key on Navigation LCD display.
5. Verify 911 Assist/VHR is in menu in Navigation LCD display.
Non Navigation Radio Instructions
911 Assist/VHR feature confirmation.
1. Press phone button on steering wheel.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency
Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact
Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 114
2. Press left arrow on steering wheel until return is displayed on radio screen, then press ok.
3. Press left arrow on steering wheel until return is displayed on radio screen, then press ok.
4. Press left arrow until 911 Assist/VHR is displayed.
Once 911 Assist/VHR installation is complete, the customer will need to reload their phone book if
that application is desired.
NOTE
IF SERVICE IS REQUIRED ON 2008 OR 2009 EARLY BUILT VEHICLES UPGRADED TO 911
ASSIST/VHR, REFERENCE THE APPLICABLE 2009 WORKSHOP MANUAL AND FOLLOW THE
V2 DIAGNOSTIC PROCEDURES.
WARRANTY STATUS: Information Only - Not Warrantable
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Entertainment System Control Module > Component Information > Technical Service Bulletins > Customer Interest: >
10-9-7 > May > 10 > Audio System - Unexpected CD Shuffle With Key Off
Entertainment System Control Module: Customer Interest Audio System - Unexpected CD Shuffle
With Key Off
TSB 10-9-7
05/24/10
UNEXPECTED COMPACT DISC SHUFFLE OR CYCLING DURING NORMAL RADIO
OPERATION OR WITH THE KEY OFF - NON-NAVIGATION RADIOS ONLY
FORD: 2008-2010 Expedition, Explorer Sport Trac, Explorer
MERCURY: 2008-2010 Mountaineer
ISSUE Some 2008-2010 Expedition, Explorer, Explorer Sport Trac and Mountaineer vehicles
equipped with a non-navigation CD-6 Audio Control Module (ACM) may experience an unexpected
Compact Disc (CD) shuffle or cycling during start up, during normal ACM operation, or shutting off
the vehicle.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
This service procedure affects non-navigation radios only. If you attempt to run module
reprogramming on the 2008-2010 ACM and the service tool does not recognize the part numbers
of the ACM currently installed, this procedure does not apply.
Reprogram the ACM to the latest calibration using IDS release 66.05A and higher. This new
calibration is not included in the VCM 2010. Version A 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
100907A 2008-2010 Expedition, 0.3 Hr.
Explorer, Mountaineer, And Explorer Sport Trac: Reprogram The Audio Control Module (Do Not
Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Entertainment System Control Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins: > 10-9-7 > May > 10 > Audio System - Unexpected CD Shuffle With Key Off
Entertainment System Control Module: All Technical Service Bulletins Audio System - Unexpected
CD Shuffle With Key Off
TSB 10-9-7
05/24/10
UNEXPECTED COMPACT DISC SHUFFLE OR CYCLING DURING NORMAL RADIO
OPERATION OR WITH THE KEY OFF - NON-NAVIGATION RADIOS ONLY
FORD: 2008-2010 Expedition, Explorer Sport Trac, Explorer
MERCURY: 2008-2010 Mountaineer
ISSUE Some 2008-2010 Expedition, Explorer, Explorer Sport Trac and Mountaineer vehicles
equipped with a non-navigation CD-6 Audio Control Module (ACM) may experience an unexpected
Compact Disc (CD) shuffle or cycling during start up, during normal ACM operation, or shutting off
the vehicle.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
This service procedure affects non-navigation radios only. If you attempt to run module
reprogramming on the 2008-2010 ACM and the service tool does not recognize the part numbers
of the ACM currently installed, this procedure does not apply.
Reprogram the ACM to the latest calibration using IDS release 66.05A and higher. This new
calibration is not included in the VCM 2010. Version A 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
100907A 2008-2010 Expedition, 0.3 Hr.
Explorer, Mountaineer, And Explorer Sport Trac: Reprogram The Audio Control Module (Do Not
Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Entertainment System Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins
for Entertainment System Control Module: > 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 (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Entertainment System Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins
for Entertainment System Control Module: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps >
Page 133
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 (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Entertainment System Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins
for Entertainment System Control Module: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps >
Page 134
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 (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Entertainment System Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins
for Entertainment System Control Module: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps >
Page 140
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 (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Entertainment System Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins
for Entertainment System Control Module: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps >
Page 141
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 (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global
Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global
Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns
Global Positioning System Module: Customer Interest SYNC(R) System - Software Update For
Various Concerns
TSB 09-26-8
01/04/10
SYNC SOFTWARE UPDATE - VARIOUS ISSUES
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009
Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner
This article supersedes TSB 9-22-14 to update the Service Procedure.
ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following
symptoms:
^ Universal Serial Bus (USB) port inoperative.
^ USB audio muting when using various non-Apple USB devices.
^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands.
^ Excessive background noise and/or poor voice sound quality.
^ Phone book auto download inoperative on supported devices.
^ SYNC steering wheel control (SWC) switches being inoperative intermittently.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace
processor (CIP) software levels.
^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report)
^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health
Report)
Service Pack files may be obtained at www.syncmyride.com.
Reprogram the APIM
Contains software fix updates for the following:
^ Phone book auto download inoperative.
^ USB audio muting.
^ SYNC steering wheel control (SWC) switches being inoperative.
^ Voice recognition on 2-digit entries.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global
Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global
Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 150
^ USB port inoperative with diagnostic trouble code (DTC) B1342.
^ Poor call sound quality.
This software update also contains enhancements that will improve the reliability of both Bluetooth
and USB connections to SYNC(R) from various consumer devices, and microphone enhancements
to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The
Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple
call handling and other mobile phone features. The USB enhancements improve support for media
players and the playing of file formats and podcasts.
NOTE
REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC
SOFTWARE PROGRAMMING TIPS.
1. Connect the vehicle communication module (VCM) to the data link connector (DLC).
2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software.
3. Turn the ignition key to the on position.
4. Launch IDS tool.
5. If required, update the VCM with the latest software.
6. Close the IDS tool.
7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle
communication is established, press the GO button.
8. From the Vehicle Service Session screen, Select the SYNC button.
9. Press read APIM button.
10. Select software and press program APIM to update the SYNC module.
NOTE
YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER
CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP.
NOTE
DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING.
NOTE
THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW
THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY
INCLUDED IN WINDOWS XP.
11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP).
NOTE
DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE.
a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the
IDS tool or laptop running IDS software and
to the vehicle USB port.
b. Follow the on-screen instructions to program both processors on the Sync module (VIP and
CIP).
12. At the end of the configuration and programming procedure, the programming has been
completed successfully screen will be displayed.
13. Exit PTS, disconnect the VCM and disconnect the USB cable.
OTHER APPLICABLE ARTICLES: 08-21-02
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
092608A 2008-2009 Edge, Explorer, 0.4 Hr.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global
Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global
Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 151
Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus,
Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty,
Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14D212 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global
Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns
Global Positioning System Module: All Technical Service Bulletins SYNC(R) System - Software
Update For Various Concerns
TSB 09-26-8
01/04/10
SYNC SOFTWARE UPDATE - VARIOUS ISSUES
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009
Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner
This article supersedes TSB 9-22-14 to update the Service Procedure.
ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following
symptoms:
^ Universal Serial Bus (USB) port inoperative.
^ USB audio muting when using various non-Apple USB devices.
^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands.
^ Excessive background noise and/or poor voice sound quality.
^ Phone book auto download inoperative on supported devices.
^ SYNC steering wheel control (SWC) switches being inoperative intermittently.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace
processor (CIP) software levels.
^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report)
^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health
Report)
Service Pack files may be obtained at www.syncmyride.com.
Reprogram the APIM
Contains software fix updates for the following:
^ Phone book auto download inoperative.
^ USB audio muting.
^ SYNC steering wheel control (SWC) switches being inoperative.
^ Voice recognition on 2-digit entries.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global
Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns >
Page 157
^ USB port inoperative with diagnostic trouble code (DTC) B1342.
^ Poor call sound quality.
This software update also contains enhancements that will improve the reliability of both Bluetooth
and USB connections to SYNC(R) from various consumer devices, and microphone enhancements
to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The
Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple
call handling and other mobile phone features. The USB enhancements improve support for media
players and the playing of file formats and podcasts.
NOTE
REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC
SOFTWARE PROGRAMMING TIPS.
1. Connect the vehicle communication module (VCM) to the data link connector (DLC).
2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software.
3. Turn the ignition key to the on position.
4. Launch IDS tool.
5. If required, update the VCM with the latest software.
6. Close the IDS tool.
7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle
communication is established, press the GO button.
8. From the Vehicle Service Session screen, Select the SYNC button.
9. Press read APIM button.
10. Select software and press program APIM to update the SYNC module.
NOTE
YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER
CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP.
NOTE
DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING.
NOTE
THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW
THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY
INCLUDED IN WINDOWS XP.
11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP).
NOTE
DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE.
a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the
IDS tool or laptop running IDS software and
to the vehicle USB port.
b. Follow the on-screen instructions to program both processors on the Sync module (VIP and
CIP).
12. At the end of the configuration and programming procedure, the programming has been
completed successfully screen will be displayed.
13. Exit PTS, disconnect the VCM and disconnect the USB cable.
OTHER APPLICABLE ARTICLES: 08-21-02
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
092608A 2008-2009 Edge, Explorer, 0.4 Hr.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global
Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns >
Page 158
Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus,
Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty,
Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14D212 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation
Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation Module: > 09-26-8 > Jan
> 10 > SYNC(R) System - Software Update For Various Concerns
Navigation Module: Customer Interest SYNC(R) System - Software Update For Various Concerns
TSB 09-26-8
01/04/10
SYNC SOFTWARE UPDATE - VARIOUS ISSUES
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009
Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner
This article supersedes TSB 9-22-14 to update the Service Procedure.
ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following
symptoms:
^ Universal Serial Bus (USB) port inoperative.
^ USB audio muting when using various non-Apple USB devices.
^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands.
^ Excessive background noise and/or poor voice sound quality.
^ Phone book auto download inoperative on supported devices.
^ SYNC steering wheel control (SWC) switches being inoperative intermittently.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace
processor (CIP) software levels.
^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report)
^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health
Report)
Service Pack files may be obtained at www.syncmyride.com.
Reprogram the APIM
Contains software fix updates for the following:
^ Phone book auto download inoperative.
^ USB audio muting.
^ SYNC steering wheel control (SWC) switches being inoperative.
^ Voice recognition on 2-digit entries.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation
Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation Module: > 09-26-8 > Jan
> 10 > SYNC(R) System - Software Update For Various Concerns > Page 167
^ USB port inoperative with diagnostic trouble code (DTC) B1342.
^ Poor call sound quality.
This software update also contains enhancements that will improve the reliability of both Bluetooth
and USB connections to SYNC(R) from various consumer devices, and microphone enhancements
to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The
Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple
call handling and other mobile phone features. The USB enhancements improve support for media
players and the playing of file formats and podcasts.
NOTE
REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC
SOFTWARE PROGRAMMING TIPS.
1. Connect the vehicle communication module (VCM) to the data link connector (DLC).
2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software.
3. Turn the ignition key to the on position.
4. Launch IDS tool.
5. If required, update the VCM with the latest software.
6. Close the IDS tool.
7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle
communication is established, press the GO button.
8. From the Vehicle Service Session screen, Select the SYNC button.
9. Press read APIM button.
10. Select software and press program APIM to update the SYNC module.
NOTE
YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER
CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP.
NOTE
DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING.
NOTE
THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW
THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY
INCLUDED IN WINDOWS XP.
11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP).
NOTE
DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE.
a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the
IDS tool or laptop running IDS software and
to the vehicle USB port.
b. Follow the on-screen instructions to program both processors on the Sync module (VIP and
CIP).
12. At the end of the configuration and programming procedure, the programming has been
completed successfully screen will be displayed.
13. Exit PTS, disconnect the VCM and disconnect the USB cable.
OTHER APPLICABLE ARTICLES: 08-21-02
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
092608A 2008-2009 Edge, Explorer, 0.4 Hr.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation
Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation Module: > 09-26-8 > Jan
> 10 > SYNC(R) System - Software Update For Various Concerns > Page 168
Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus,
Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty,
Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14D212 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation Module: >
09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns
Navigation Module: All Technical Service Bulletins SYNC(R) System - Software Update For
Various Concerns
TSB 09-26-8
01/04/10
SYNC SOFTWARE UPDATE - VARIOUS ISSUES
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009
Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner
This article supersedes TSB 9-22-14 to update the Service Procedure.
ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following
symptoms:
^ Universal Serial Bus (USB) port inoperative.
^ USB audio muting when using various non-Apple USB devices.
^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands.
^ Excessive background noise and/or poor voice sound quality.
^ Phone book auto download inoperative on supported devices.
^ SYNC steering wheel control (SWC) switches being inoperative intermittently.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace
processor (CIP) software levels.
^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report)
^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health
Report)
Service Pack files may be obtained at www.syncmyride.com.
Reprogram the APIM
Contains software fix updates for the following:
^ Phone book auto download inoperative.
^ USB audio muting.
^ SYNC steering wheel control (SWC) switches being inoperative.
^ Voice recognition on 2-digit entries.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation Module: >
09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 174
^ USB port inoperative with diagnostic trouble code (DTC) B1342.
^ Poor call sound quality.
This software update also contains enhancements that will improve the reliability of both Bluetooth
and USB connections to SYNC(R) from various consumer devices, and microphone enhancements
to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The
Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple
call handling and other mobile phone features. The USB enhancements improve support for media
players and the playing of file formats and podcasts.
NOTE
REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC
SOFTWARE PROGRAMMING TIPS.
1. Connect the vehicle communication module (VCM) to the data link connector (DLC).
2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software.
3. Turn the ignition key to the on position.
4. Launch IDS tool.
5. If required, update the VCM with the latest software.
6. Close the IDS tool.
7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle
communication is established, press the GO button.
8. From the Vehicle Service Session screen, Select the SYNC button.
9. Press read APIM button.
10. Select software and press program APIM to update the SYNC module.
NOTE
YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER
CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP.
NOTE
DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING.
NOTE
THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW
THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY
INCLUDED IN WINDOWS XP.
11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP).
NOTE
DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE.
a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the
IDS tool or laptop running IDS software and
to the vehicle USB port.
b. Follow the on-screen instructions to program both processors on the Sync module (VIP and
CIP).
12. At the end of the configuration and programming procedure, the programming has been
completed successfully screen will be displayed.
13. Exit PTS, disconnect the VCM and disconnect the USB cable.
OTHER APPLICABLE ARTICLES: 08-21-02
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
092608A 2008-2009 Edge, Explorer, 0.4 Hr.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation Module: >
09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 175
Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus,
Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty,
Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14D212 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 151-24
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Locations > Page 179
View 151-25
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Locations > Page 180
View 151-26
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Locations > Page 181
Parking Assist Control Module: Diagrams
C3267
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Locations > Page 182
C4014
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Locations > Page 183
C4226
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Locations > Page 184
Parking Assist Control Module: Service and Repair
PARKING AID MODULE
Removal and Installation
1. Disconnect the parking aid module (PAM) 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 PAM bumper harness from the PAM. 5. Remove the 2 PAM
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 (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module >
Component Information > Locations
View 151-28
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module >
Component Information > Locations > Page 189
Memory Positioning Module: Diagrams
C341A
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module >
Component Information > Locations > Page 190
C341B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module >
Component Information > Locations > Page 191
C341C
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module >
Component Information > Locations > Page 192
Memory Positioning Module: Service and Repair
DRIVER SEAT MODULE (DSM)
Special Tool(s)
Special Tool(s)
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module >
Component Information > Locations > Page 193
Part 2
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. NOTE: This step is necessary only if the DSM is being replaced.
Upload the module configuration information from the DSM.
2. Remove the driver seat. 3. Remove the 2 DSM screws. 4. Disconnect the electrical connectors
and remove the DSM.
5. NOTE: Once the module is installed (if it was replaced) 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 (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay >
Component Information > Locations > Third Row Folding Seat Relay, Left
Power Seat Relay: Locations Third Row Folding Seat Relay, Left
View 151-22
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay >
Component Information > Locations > Third Row Folding Seat Relay, Left > Page 198
View 151-30
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay >
Component Information > Locations > Third Row Folding Seat Relay, Left > Page 199
Power Seat Relay: Locations Third Row Folding Seat Relay, Right
View 151-22
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay >
Component Information > Locations > Third Row Folding Seat Relay, Left > Page 200
View 151-30
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 203
C4184
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Power Seat Relay: Testing and Inspection Third Row Folding Seat Relay, Left
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 206
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 207
Power Seat Relay: Testing and Inspection Third Row Folding Seat Relay, Right
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 208
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Auxiliary Step / Running Board
Module > Component Information > Locations
View 151-24
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Auxiliary Step / Running Board
Module > Component Information > Locations > Page 212
Auxiliary Step / Running Board Module: Diagrams
C4322A
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Auxiliary Step / Running Board
Module > Component Information > Locations > Page 213
C4322B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Auxiliary Step / Running Board
Module > Component Information > Locations > Page 214
Auxiliary Step / Running Board Module: Service and Repair
POWER RUNNING BOARD (PRB) MODULE
Removal and Installation
1. Remove the RH C-pillar trim panel. 2. Disconnect the power running board (PRB) module
electrical connectors. 3. Remove the 3 screws and the PRB module assembly.
- To install, tighten to 7 Nm (62 lb-in).
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module >
Component Information > Locations
Sunroof / Moonroof Module: Locations
View 151-36
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module >
Component Information > Locations > Page 218
View 151-37
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module >
Component Information > Locations > Page 219
C921
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay >
Component Information > Locations > Page 223
Trailer Towing Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Locations
Electronic Brake Control Module: Locations
View 151-2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Locations > Page 228
View 151-5
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Locations > Page 229
Electronic Brake Control Module: Diagrams
C155 (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Locations > Page 230
C155 (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Locations > Page 231
Electronic Brake Control Module: Service and Repair
Anti-Lock Brake System (ABS) Module
Removal and Installation
CAUTION: Electronic modules are sensitive to electrical charges. The anti-lock brake system
(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 Programmable Module Installation in Information Bus (Module Configuration).
1. Remove the hydraulic control unit (HCU). 2. Remove the 4 screws and the ABS module.
^ To install, tighten to 2 Nm (18 lb-in).
3. CAUTION: Make sure that the anti-lock brake system (ABS) module is properly seated to the
hydraulic control unit (HCU) and that the
torque of the ABS module screws is correct, or damage to the components can occur.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake
Control Module > Component Information > Locations
View 151-13
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake
Control Module > Component Information > Locations > Page 235
C239
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Auxiliary Blower Motor Relay
View 151-40
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Auxiliary Blower Motor Relay > Page 241
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Auxiliary Blower Motor Relay > Page 242
View 151-38
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Diagrams > Auxiliary Blower Motor Relay
C3023
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Diagrams > Auxiliary Blower Motor Relay > Page 245
C2017
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > Blower Motor Relay
Blower Motor Relay: Testing and Inspection Blower Motor Relay
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > Blower Motor Relay > Page 248
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > Blower Motor Relay > Page 249
Blower Motor Relay: Testing and Inspection Auxiliary Blower Motor Relay
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > Blower Motor Relay > Page 250
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Page 254
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 (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Page 255
Compressor Clutch Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Locations > Page 259
Control Module HVAC: Diagrams
C228A
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Locations > Page 260
C228B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module
> Component Information > Technical Service Bulletins > Customer Interest: > 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 (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module
> Component Information > Technical Service Bulletins > Customer Interest: > 09-21-7 > Nov > 09 > Instruments - Trip
Odometers/Fuel Economy Resets > Page 270
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module
> Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 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 (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module
> Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-21-7 > Nov > 09 >
Instruments - Trip Odometers/Fuel Economy Resets > Page 276
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Distance/Mileage Module: >
10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling
Wheel Cover: All Technical Service Bulletins Wheels - 20 Inch Wheels Clear Coat
Cracking/Peeling
TSB 10-11-2
06/21/10
20 INCH POLISHED ALUMINUM WHEEL - CORROSION AND ETCHING
FORD: 2008-2010 Explorer Sport Trac, Explorer
MERCURY: 2008-2010 Mountaineer
ISSUE Some 2008-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with
20-inch aluminum wheels may exhibit the clear coat peeling off the wheel and/or cracks in the clear
coat that look like spider webs. This may be due to a galvanic corrosion reaction between the
aluminum wheel and the chrome center wheel cap.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Replace the affected wheel or wheels and install new center wheel caps that prevent the corrosion.
1. Inspect wheel(s) for cracked or peeling clear coat. (Figure 1)
NOTE
CONDITIONS ATTRIBUTABLE TO DAMAGE ARE NOT ELIGIBLE FOR COVERAGE UNDER
WARRANTY. REFER TO WARRANTY AND POLICY MANUAL FOR ADDITIONAL
INFORMATION.
2. To service, replace only affected wheel or wheels and install new center wheel caps. Refer to
Workshop Manual, Section 204-04, for wheel removal
and installation procedures including tire/wheel disassembly/assembly to prevent damage to the
tire pressure monitoring system (TPMS) sensor.
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Distance/Mileage Module: >
10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling > Page 282
101102A 2008-2010 0.6 Hr.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace One Wheel And Center
Wheel Cap (Do Not Use With Any Other Labor Operations)
101102B 2008-2010 0.9 Hr.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Two Wheels And Center
Wheel Caps (Do Not Use With Any Other Labor Operations)
101102C 2008-2010 1.2 Hrs.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Three Wheels And Center
Wheels Caps (Do Not Use With Any Other Labor Operations)
101102D 2008-2010 1.5 Hrs.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Four Wheels And Center
Wheel Caps (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 14
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Distance/Mileage Module: >
10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling > Page 288
101102A 2008-2010 0.6 Hr.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace One Wheel And Center
Wheel Cap (Do Not Use With Any Other Labor Operations)
101102B 2008-2010 0.9 Hr.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Two Wheels And Center
Wheel Caps (Do Not Use With Any Other Labor Operations)
101102C 2008-2010 1.2 Hrs.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Three Wheels And Center
Wheels Caps (Do Not Use With Any Other Labor Operations)
101102D 2008-2010 1.5 Hrs.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Four Wheels And Center
Wheel Caps (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 14
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 297
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 303
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations > Page 308
Fog/Driving Lamp Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Locations > Page 315
Trailer Lighting Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay
> Component Information > Testing and Inspection
Micro ISO Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay >
Component Information > Testing and Inspection
Mini ISO Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Module > Component Information > Service and Repair
Power Distribution Module: Service and Repair
SMART JUNCTION BOX (SJB)
Special Tool(s)
Special Tool(s)
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Module > Component Information > Service and Repair > Page 326
Part 2
Removal
CAUTION:
- If the SJB is dropped, damage to the internal components may occur. A new SJB must be
installed.
- Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage
may result.
NOTE:
- Prior to the replacement of the module, it is necessary to upload the module configuration
information into the appropriate scan tool. This information must be downloaded into the new
module after installation.
- The tire pressure monitoring system (TPMS) functionality is integral to the SJB.
- 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 a manufacturing mode with 6 pre-set DTCs related to the TPMS. To clear the DTCs, successful
configuration of the SJB must occur, followed by successful TPMS sensor training, and a
successful self-test, including clearing of the DTCs. The DTCs are as follows: B2477 (Module Configuration Failure)
- B2868 (Left Front Tire Pressure Sensor Fault)
- B2869 (Right Front Tire Pressure Sensor Fault)
- B2870 (Right Rear Tire Pressure Sensor Fault)
- B2871 (Left Rear Tire Pressure Sensor Fault)
- C2780 (ECU in Manufacturer Sub-State)
1. NOTE: This step is necessary only if the SJB is being replaced.
Upload the module configuration information from the SJB.
2. Remove the driver door scuff plate. 3. Position the LH door opening weather seal aside.
4. 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.
5. Remove the 2 bolts and the parking brake release handle. 6. Disconnect the parking brake
switch electrical connector. 7. Release the hood release cable pushpin from the parking brake
control bracket. 8. Release the harness clip from the parking brake cable housing.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Module > Component Information > Service and Repair > Page 327
9. 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.
10. 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 (then lift it upward to disengage the lower tangs from the instrument panel),
disconnect the 2 electrical connectors and position the bezel assembly aside.
11 If necessary, push the LH instrument panel side finish panel out and position it aside.
12. Through the headlight switch bezel opening, remove the 2 SJB bolts. 13. From under the
instrument panel, remove the third (lower right) SJB bolt.
14. 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.
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 be present
in order 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 lower, right 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. 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.
12. Position the LH door opening weather seal.
13. NOTE: If the SJB was not replaced, this is the last step that is necessary.
Install the driver door scuff plate.
14. NOTE:
- When successful, this step provides the calibration necessary for the SJB operation and clears
DTC B2477. The clearing of this DTC indicates the calibration data has been successfully
downloaded to the new SJB.
- When successful, this step also programs the remote transmitters into the new SJB. In the event
the remote transmitters do not program to the new SJB, all of the remote transmitters will need to
be present and refer to Locks, Remote Keyless Entry Transmitter Programming. This action will
program the remote transmitters into the new SJB. See: Accessories and Optional
Equipment/Antitheft and Alarm Systems/Keyless Entry/Keyless Entry Transmitter/Testing and
Inspection/Remote Keyless Entry Transmitter Programming
Download the SJB configuration information from the scan tool into the new SJB.
15. 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Module > Component Information > Service and Repair > Page 328
16. NOTE: DTC C2780 will not clear if any of the pre-set DTCs are still present in the SJB. When
successful, this step will clear the DTC C2780.
Carry out the SJB on-demand self-test by clearing DTCs, and then retrieving DTCs to confirm all
DTCs have been cleared.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 336
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 337
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 338
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 339
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 340
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 341
Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 342
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 343
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 344
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 345
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 346
Relay Box: Locations Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Battery Junction Box (BJB) > Page 349
Relay Box: Diagrams Smart Junction Box (SJB)
C2280A (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Battery Junction Box (BJB) > Page 350
C2280A (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Battery Junction Box (BJB) > Page 351
C2280B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Battery Junction Box (BJB) > Page 352
C2280C
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Battery Junction Box (BJB) > Page 353
C2280D
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Battery Junction Box (BJB) > Page 354
C2280E
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
357
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
358
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page
359
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page
360
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page
361
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
362
Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page
363
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
364
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page
365
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page
366
Battery Junction Box (BJB) / Power Distribution Box
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Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page
367
Relay Box: Application and ID Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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.
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
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: -
The throttle actuator control (TAC) motor is a DC motor controlled by the PCM (requires 2-wires).
- There are 2 designs: parallel and in-line. 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-line design has a
separate motor housing.
- An internal spring is used in both designs to return the throttle plate to a default position. The
default position is typically a throttle angle of 7 to 8 degrees from the hard stop angle.
- The closed throttle plate hard stop is used to prevent the throttle from binding in the bore
(approximately 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.
- 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.
- There is 1 reference voltage and 1 signal return circuit between the PCM and the ETB. The
reference voltage circuit and the signal return circuit is shared with the reference voltage circuits
and signal return circuits used by the APP sensor. There are also 2 TP signal circuits for
redundancy. The redundant TP 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). The TP2 signal reaches a limit of
approximately 4.5 volts at approximately 45 degrees of throttle angle.
Accelerator Pedal Position (APP) Sensor
Depending on the application either a 2-track or 3-track APP sensor is used.
Electronic Throttle Control (ETC) System Strategy
ETC System With A 3-Track APP Sensor Failure Mode And Effects Management (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 373
ETC System With A 3-Track APP Sensor Failure Mode And Effects Management (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 374
ETC System With A 2-Track APP Sensor Failure Mode And Effects Management
Electronic Throttle Monitor Operation
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 375
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 separate monitoring 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, appropriate corrective action is taken.
APP and TP Sensor Inputs
Accelerator Pedal Position (APP) Sensor Check
Throttle Position (TP) Sensor Check
Electronic Throttle Actuator Control (TAC) Output
Electronic TAC Operation Check
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 for Engine Control Module: > 09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC P0196/RPM
Loss/Slow Idle
Engine Control Module: Customer Interest Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow
Idle
TSB 09-22-6
11/16/09
4.6L ENGINE -CHECK ENGINE LIGHT ON - DTC P0196 - COLD WEATHER DRIVING
CONDITIONS- CALIBRATION UPDATE
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
ISSUE Some 2006-2008 Explorer, Mountaineer and Sport Trac vehicles and equipped with 4.6L
3-V engines may exhibit:
^ Diagnostic trouble code (DTC) P0196 - engine oil temperature (EOT) sensor range/performance
during ice/snow driving conditions.
^ Idle speed dropping below specification, hesitation or loss of RPM with no DTCs stored in the
Powertrain Control Module (PCM).
^ Cruise control surge at approximately 50-60 MPH (80-97 Km/h) in hilly regions Only applies to
vehicles operated in altitudes above 5000 feet (1.52
km).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
If normal Powertrain Controls/Emissions Diagnosis (PC/ED) diagnostics do not resolve the above
vehicle concerns, reprogram the PCM and Transmission Control Module (1CM) to the latest
calibration using IDS release 63.08 and higher. This new calibration is not included in the VCM
2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
VEHICLES EQUIPPED WITH A PCM AND TCM, REQUIRE A COORDINATED
REPROGRAMMING.
THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS
OUTLINED BY THE INTERGRATED DIAGNOSTIC SYSTEM (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 63.08 and higher. This new calibration
is not included in the VCM 2009.9 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:
(1) Choose all Tests and Calibrations.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 for Engine Control Module: > 09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC P0196/RPM
Loss/Slow Idle > Page 384
(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
DISCONNECTING 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 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. Brake gently to a complete
stop and hold foot on brake for at least 10 seconds.
g. Repeat Steps (e-f) a total of three (3) 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
092206A 2006-2008 Explorer, 1.0 Hr.
Mountaineer 2007-2008 Explorer Sport Trac: Check DTCs, Reprogram The PCM And TCM
Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor
Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 for Engine Control Module: > 09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC P0196/RPM
Loss/Slow Idle
Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0196/RPM
Loss/Slow Idle
TSB 09-22-6
11/16/09
4.6L ENGINE -CHECK ENGINE LIGHT ON - DTC P0196 - COLD WEATHER DRIVING
CONDITIONS- CALIBRATION UPDATE
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
ISSUE Some 2006-2008 Explorer, Mountaineer and Sport Trac vehicles and equipped with 4.6L
3-V engines may exhibit:
^ Diagnostic trouble code (DTC) P0196 - engine oil temperature (EOT) sensor range/performance
during ice/snow driving conditions.
^ Idle speed dropping below specification, hesitation or loss of RPM with no DTCs stored in the
Powertrain Control Module (PCM).
^ Cruise control surge at approximately 50-60 MPH (80-97 Km/h) in hilly regions Only applies to
vehicles operated in altitudes above 5000 feet (1.52
km).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
If normal Powertrain Controls/Emissions Diagnosis (PC/ED) diagnostics do not resolve the above
vehicle concerns, reprogram the PCM and Transmission Control Module (1CM) to the latest
calibration using IDS release 63.08 and higher. This new calibration is not included in the VCM
2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
VEHICLES EQUIPPED WITH A PCM AND TCM, REQUIRE A COORDINATED
REPROGRAMMING.
THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS
OUTLINED BY THE INTERGRATED DIAGNOSTIC SYSTEM (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 63.08 and higher. This new calibration
is not included in the VCM 2009.9 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:
(1) Choose all Tests and Calibrations.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 for Engine Control Module: > 09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC P0196/RPM
Loss/Slow Idle > Page 390
(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
DISCONNECTING 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 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. Brake gently to a complete
stop and hold foot on brake for at least 10 seconds.
g. Repeat Steps (e-f) a total of three (3) 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
092206A 2006-2008 Explorer, 1.0 Hr.
Mountaineer 2007-2008 Explorer Sport Trac: Check DTCs, Reprogram The PCM And TCM
Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor
Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
391
Engine Control Module: Locations
View 151-1
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392
View 151-4
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393
View 151-8
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394
View 151-10
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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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
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and Instructions > Page 397
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
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and Instructions > Page 398
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
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and Instructions > Page 399
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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and Instructions > Page 400
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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and Instructions > Page 401
Symbols (Part 3)
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and Instructions > Page 402
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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and Instructions > Page 403
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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and Instructions > Page 404
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
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and Instructions > Page 405
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
3 = Splice tape
4 = Harness tape
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and Instructions > Page 406
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.
3. lnstall 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 seat wire splice.
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and Instructions > Page 407
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.
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 6.35mm (1/4 in) 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.
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and Instructions > Page 408
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.
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, barrel squeeze tool handles appropriate 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.
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and Instructions > Page 409
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
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and Instructions > Page 410
Engine Control Module: Connector Views
C175B (Part 1)
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and Instructions > Page 411
C175B (Part 2)
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and Instructions > Page 412
C175E (Part 1)
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and Instructions > Page 413
C175E (Part 2)
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and Instructions > Page 414
C175E (Part 3)
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and Instructions > Page 415
C175T (Part 1)
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and Instructions > Page 416
C175T (Part 2)
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Engine Control Module: Procedures
FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM)
Description
The EEPROM is contained in an integrated circuit 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 PI635 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 (V8-4.6L (2008))
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 > Procedures >
Page 419
Engine Control Module: Removal and Replacement
POWERTRAIN CONTROL MODULE (PCM)
A/C Tube Brackets
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Procedures >
Page 420
PCM
Removal
All vehicles
1. NOTE: 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 3. Disconnect the RH front wheel speed sensor electrical connector. Remove the nut(s)
and position the A/C tube bracket(s) 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
bracket(s) and install the nut(s). Connect the RH front wheel speed sensor electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Procedures >
Page 421
- 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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 425
Main Relay (Computer/Fuel System): Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Emission Control Systems > EGR Control Module > Component Information > Locations
View 151-7
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Emission Control Systems > EGR Control Module > Component Information > Locations > Page 430
C1450
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Fuel Pump Control Unit: Locations
View 151-24
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 435
View 151-27
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 436
C4033
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 437
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 441
Fuel Pump Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 445
Main Relay (Computer/Fuel System): Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations
Air Bag Control Module: Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 450
View 151-18
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 451
View 151-21
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Diagrams > Driver Can Vent Unit
C216C
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Diagrams > Driver Can Vent Unit > Page 454
Air Bag Control Module: Diagrams Restraints Control Module
C310A
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Diagrams > Driver Can Vent Unit > Page 455
C310B (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Diagrams > Driver Can Vent Unit > Page 456
C310B (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Diagrams > Page 457
Air Bag Control Module: Service and Repair
RESTRAINTS CONTROL MODULE (RCM)
Special Tool(s)
Special Tool(s)
Removal
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 this
instruction may result in the accidental deployment of the safety canopy and cause serious
personal injury or death.
- If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact
sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the
original production configuration. A new RCM and sensors must be installed whether or not the air
bags have deployed. Failure to follow these instructions may result in serious personal injury or
death in a crash.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Diagrams > Page 458
- Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if
equipped) to the specified torque. Failure to do so may result in incorrect restraint system
operation, which increases the risk of personal injury or death in a crash.
CAUTION: When installing a new RCM, it is necessary to carry out programmable module
installation (PMI). System failure may occur if PMI is not performed.
NOTE:
- When installing a new restraints control module (RCM), always make sure the correct RCM is
being installed. If an incorrect RCM is installed, erroneous DTCs will result.
- The air bag warning indicator 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. Carry out the steps necessary to prepare for programmable module installation (PMI). 2.
Depower the SRS. 3. Remove the front floor console. 4. Disconnect the large 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
1. Install the RCM. 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Diagrams > Page 459
5. CAUTION: Putting the large restraints control module (RCM) electrical connector into the RCM
on an angle may cause bad electrical
connections and damage components.
Position the large RCM electrical connector into the RCM.
6. Connect the large RCM connector.
- CAUTION: Do not push the connector to the point where the lever pivots and seats itself. Light
pressure is needed to get the connector into position on the restraints control module (RCM),
before using the lever to fully seat the connector. Damage to the connector or component may
occur.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Diagrams > Page 460
7. Install the front floor console. 8. Repower the SRS. Do not prove out the SRS at this time. 9.
Carry out the steps necessary to complete PMI.
10. 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 warning indicator with the air bag modules installed. The air bag
warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag
SRS fault is present, the air bag warning indicator will: fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag warning 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 warning 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 warning
indicator and any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the RCM and occupant classification system module (OCSM)
using a scan tool.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification
Module - Air Bag > Component Information > Locations
View 151-29
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification
Module - Air Bag > Component Information > Locations > Page 464
C3159
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification
Module - Air Bag > Component Information > Locations > Page 465
Seat Occupant Classification Module - Air Bag: Service and Repair
OCCUPANT CLASSIFICATION SYSTEM MODULE (OCSM)
Removal and Installation
NOTE:
- The air bag warning indicator 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 seat similar.
- Seat is removed for clarity.
1. Depower the SRS. 2. From underneath the front of the seat, disconnect the occupant
classification system module (OCSM) electrical connector.
3. NOTE: Note the position of the locator tab on the OCSM for installation.
Remove the 2 screws and the OCSM. 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. 4. To install, reverse the removal procedure. 5. Repower the SRS. Do not prove out the SRS
at this time. 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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification
Module - Air Bag > Component Information > Locations > Page 466
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/Occupant Classification Sensor (OCS) System Reset
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Starter Relay
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Starter Relay > Page 472
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Testing and Inspection > Run/Start Relay
Starter Relay: Testing and Inspection Run/Start Relay
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Testing and Inspection > Run/Start Relay > Page 475
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Testing and Inspection > Run/Start Relay > Page 476
Starter Relay: Testing and Inspection Starter Relay
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Testing and Inspection > Run/Start Relay > Page 477
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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:
> 09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle
Control Module: Customer Interest Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle
TSB 09-22-6
11/16/09
4.6L ENGINE -CHECK ENGINE LIGHT ON - DTC P0196 - COLD WEATHER DRIVING
CONDITIONS- CALIBRATION UPDATE
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
ISSUE Some 2006-2008 Explorer, Mountaineer and Sport Trac vehicles and equipped with 4.6L
3-V engines may exhibit:
^ Diagnostic trouble code (DTC) P0196 - engine oil temperature (EOT) sensor range/performance
during ice/snow driving conditions.
^ Idle speed dropping below specification, hesitation or loss of RPM with no DTCs stored in the
Powertrain Control Module (PCM).
^ Cruise control surge at approximately 50-60 MPH (80-97 Km/h) in hilly regions Only applies to
vehicles operated in altitudes above 5000 feet (1.52
km).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
If normal Powertrain Controls/Emissions Diagnosis (PC/ED) diagnostics do not resolve the above
vehicle concerns, reprogram the PCM and Transmission Control Module (1CM) to the latest
calibration using IDS release 63.08 and higher. This new calibration is not included in the VCM
2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
VEHICLES EQUIPPED WITH A PCM AND TCM, REQUIRE A COORDINATED
REPROGRAMMING.
THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS
OUTLINED BY THE INTERGRATED DIAGNOSTIC SYSTEM (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 63.08 and higher. This new calibration
is not included in the VCM 2009.9 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:
(1) Choose all Tests and Calibrations.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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:
> 09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle > Page 488
(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
DISCONNECTING 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 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. Brake gently to a complete
stop and hold foot on brake for at least 10 seconds.
g. Repeat Steps (e-f) a total of three (3) 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
092206A 2006-2008 Explorer, 1.0 Hr.
Mountaineer 2007-2008 Explorer Sport Trac: Check DTCs, Reprogram The PCM And TCM
Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor
Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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: > 09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle
Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0196/RPM
Loss/Slow Idle
TSB 09-22-6
11/16/09
4.6L ENGINE -CHECK ENGINE LIGHT ON - DTC P0196 - COLD WEATHER DRIVING
CONDITIONS- CALIBRATION UPDATE
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
ISSUE Some 2006-2008 Explorer, Mountaineer and Sport Trac vehicles and equipped with 4.6L
3-V engines may exhibit:
^ Diagnostic trouble code (DTC) P0196 - engine oil temperature (EOT) sensor range/performance
during ice/snow driving conditions.
^ Idle speed dropping below specification, hesitation or loss of RPM with no DTCs stored in the
Powertrain Control Module (PCM).
^ Cruise control surge at approximately 50-60 MPH (80-97 Km/h) in hilly regions Only applies to
vehicles operated in altitudes above 5000 feet (1.52
km).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
If normal Powertrain Controls/Emissions Diagnosis (PC/ED) diagnostics do not resolve the above
vehicle concerns, reprogram the PCM and Transmission Control Module (1CM) to the latest
calibration using IDS release 63.08 and higher. This new calibration is not included in the VCM
2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
VEHICLES EQUIPPED WITH A PCM AND TCM, REQUIRE A COORDINATED
REPROGRAMMING.
THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS
OUTLINED BY THE INTERGRATED DIAGNOSTIC SYSTEM (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 63.08 and higher. This new calibration
is not included in the VCM 2009.9 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:
(1) Choose all Tests and Calibrations.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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: > 09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle > Page 494
(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
DISCONNECTING 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 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. Brake gently to a complete
stop and hold foot on brake for at least 10 seconds.
g. Repeat Steps (e-f) a total of three (3) 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
092206A 2006-2008 Explorer, 1.0 Hr.
Mountaineer 2007-2008 Explorer Sport Trac: Check DTCs, Reprogram The PCM And TCM
Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor
Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Page 495
View 151-12
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Page 496
C199
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules
- Transfer Case > Control Module, Transfer Case > Component Information > Diagrams
C2260
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element
Relay > Component Information > Locations > Rear Window Defrost Relay > Page 506
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element
Relay > Component Information > Locations > Rear Window Defrost Relay > Page 507
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Heated Glass Element Relay: Testing and Inspection Rear Window Defrost Relay
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 510
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 511
Heated Glass Element Relay: Testing and Inspection Heated Windshield Relay, Left
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 512
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 513
Heated Glass Element Relay: Testing and Inspection Heated Windshield Relay, Right
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 514
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Locations
View 151-35
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Locations > Page 519
C4323
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Locations > Page 523
Wiper Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Locations
Parking Assist Distance Sensor: Locations
View 151-26
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Locations > Page 529
View 151-27
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 532
C4011
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 533
C4010
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 534
C4012
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal
Positioning Switch > Component Information > Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal
Positioning Switch > Component Information > Locations > Page 538
C2089
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote
Switch, Audio - Stereo > Component Information > Locations
View 151-16
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote
Switch, Audio - Stereo > Component Information > Locations > Page 542
C2208
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch >
Component Information > Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch >
Component Information > Locations > Page 547
C2089
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 151-32
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 552
View 151-31
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 555
C605
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Page 556
Power Door Lock Switch: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Page 557
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Page 558
- Release the 4 retaining tabs.
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations
View 151-31
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 562
C527
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 563
Power Mirror Switch: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 564
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 565
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 (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Third Row Folding Seat Switch
Power Seat Switch: Locations Third Row Folding Seat Switch
View 151-22
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Third Row Folding Seat Switch > Page 570
View 151-30
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Third Row Folding Seat Switch > Page 571
View 151-22
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Third Row Folding Seat Switch > Page 572
View 151-30
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Third Row Folding Seat Switch > Page 573
Power Seat Switch: Locations Power Seat Switch
View 151-28
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Third Row Folding Seat Switch > Page 574
View 151-29
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Diagrams > Power Seat Switch
Power Seat Switch: Diagrams Power Seat Switch
C352
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Diagrams > Power Seat Switch > Page 577
C3016
C355
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Diagrams > Power Seat Switch > Page 578
Power Seat Switch: Diagrams Third Row Folding Seat Switch
C4179
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Diagrams > Power Seat Switch > Page 579
C4180
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Power Seat Switch, Left - 10-Way Power Seat
Power Seat Switch: Testing and Inspection Power Seat Switch, Left - 10-Way Power Seat
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Power Seat Switch, Left - 10-Way Power Seat > Page 582
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Power Seat Switch, Left - 10-Way Power Seat > Page 583
Power Seat Switch: Testing and Inspection Power Seat Switch, Left - 6-Way Power Seat
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Power Seat Switch, Left - 10-Way Power Seat > Page 584
Power Seat Switch: Testing and Inspection Power Seat Switch, Right
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Page 585
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 (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock
Switch > Component Information > Locations
View 151-35
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock
Switch > Component Information > Locations > Page 589
C4039
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Locations > Page 593
C2347
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Service and Repair > Heated Seat Switch > Page 596
Seat Heater Switch: Service and Repair Seat Control Switch
SEAT CONTROL SWITCH
Exploded View
Front Seat Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Service and Repair > Heated Seat Switch > Page 597
Front Seat Backrest (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Service and Repair > Heated Seat Switch > Page 598
Driver Seat Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Service and Repair > Heated Seat Switch > Page 599
Driver Seat Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Service and Repair > Heated Seat Switch > Page 600
Passenger Seat Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Service and Repair > Heated Seat Switch > Page 601
Passenger Seat Cushion (Part 2)
Special Tool(s)
Special Tool(s)
Removal and Installation
NOTE:
- The air bag warning indicator 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.
All seats
1. Remove the front seat. 2. Remove the cushion side shield in the following sequence.
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. If a passenger seat has been serviced, do not prove out the SRS at this time.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Service and Repair > Heated Seat Switch > Page 602
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 (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Service and Repair > Heated Seat Switch > Page 603
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 (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch >
Component Information > Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch >
Component Information > Locations > Page 607
C2094
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch
> Component Information > Locations
Sunroof / Moonroof Switch: Locations
View 151-36
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch
> Component Information > Locations > Page 611
View 151-37
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch
> Component Information > Locations > Page 612
Sunroof / Moonroof Switch: Diagrams
C912
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch
> Component Information > Locations > Page 613
C9001
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch
> Component Information > Locations > Page 614
C9038
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch
> Component Information > Testing and Inspection > Roof Opening Panel Switch
Sunroof / Moonroof Switch: Testing and Inspection Roof Opening Panel Switch
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch
> Component Information > Testing and Inspection > Roof Opening Panel Switch > Page 617
Sunroof / Moonroof Switch: Testing and Inspection Roof Opening Panel Switch With Rear Window
Motor
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch
> Component Information > Testing and Inspection > Roof Opening Panel Switch > Page 618
Sunroof / Moonroof Switch: Testing and Inspection Roof Opening Panel Switch With Medium
Overhead Console
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch
> Component Information > Testing and Inspection > Page 619
Sunroof / Moonroof 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 (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar Switch
> Component Information > Locations
View 151-35
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar Switch
> Component Information > Locations > Page 623
C479
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > ABS Sensor
Block > Component Information > Locations
View 151-17
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > ABS Sensor
Block > Component Information > Locations > Page 628
C3073
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > ABS Sensor
Block > Component Information > Locations > Page 629
ABS Sensor Block: Service and Repair
Stability Control Sensor Cluster
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > ABS Sensor
Block > Component Information > Locations > Page 630
Removal and Installation
NOTE: When installing a new stability control sensor cluster, the ABS module must be calibrated.
Follow the scan tool directions for the calibration procedures.
1. Remove the pin-type retainer and the LH floor console finish panel. 2. Remove the 2 bolts, 2
nuts and the LH instrument panel brace.
^ To install, tighten to 9 Nm (80 lb-in).
3. Remove the 2 bolts and LH floor 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 lb-in).
7. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster
Vacuum Sensor > Component Information > Locations
Brake Booster Vacuum Sensor: Locations
View 151-2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster
Vacuum Sensor > Component Information > Locations > Page 634
View 151-5
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster
Vacuum Sensor > Component Information > Locations > Page 635
C149
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations
Brake Fluid Level Sensor/Switch: Locations
View 151-1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations > Page 639
View 151-4
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations > Page 640
C124
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral
Accelerometer > Component Information > Service and Repair > Page 644
Removal and Installation
NOTE: When installing a new stability control sensor cluster, the ABS module must be calibrated.
Follow the scan tool directions for the calibration procedures.
1. Remove the pin-type retainer and the LH floor console finish panel. 2. Remove the 2 bolts, 2
nuts and the LH instrument panel brace.
^ To install, tighten to 9 Nm (80 lb-in).
3. Remove the 2 bolts and LH floor 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 lb-in).
7. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake
Warning Switch > Component Information > Locations
Parking Brake Warning Switch: Locations
View 151-18
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake
Warning Switch > Component Information > Locations > Page 648
View 151-19
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake
Warning Switch > Component Information > Locations > Page 649
C2015
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
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 (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control
Switch > Component Information > Locations
View 151-13
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control
Switch > Component Information > Locations > Page 656
C280
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control
Switch > Component Information > Locations > Page 657
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 lb-in).
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control
Switch > Component Information > Locations > Page 658
5. Disconnect the stability traction control switch electrical connector and remove the stability
traction control switch from the instrument panel
center finish panel.
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front
Wheel Speed Sensor: Locations Wheel Speed Sensor, Left Front
View 151-2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 663
View 151-5
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 664
Wheel Speed Sensor: Locations Wheel Speed Sensor, Right Front
View 151-2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 665
View 151-5
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 666
Wheel Speed Sensor: Locations Wheel Speed Sensor, Left Rear
View 151-22
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 667
View 151-27
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 668
Wheel Speed Sensor: Locations Wheel Speed Sensor, Right Rear
View 151-24
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 669
View 151-27
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front
C150
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 672
C160
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 673
C440
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 674
C426
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
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. 4. Remove the wheel speed sensor harness
pin-type retainers. 5. Remove the wheel speed sensor bolt.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 677
^ To install, tighten to 17 Nm (13 lb-ft).
6. Remove the wheel speed sensor and the harness. 7. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 678
Wheel Speed Sensor: Service and Repair 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 lb-in).
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Service and Repair
Yaw Rate Sensor: Service and Repair
Stability Control Sensor Cluster
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Service and Repair > Page 682
Removal and Installation
NOTE: When installing a new stability control sensor cluster, the ABS module must be calibrated.
Follow the scan tool directions for the calibration procedures.
1. Remove the pin-type retainer and the LH floor console finish panel. 2. Remove the 2 bolts, 2
nuts and the LH instrument panel brace.
^ To install, tighten to 9 Nm (80 lb-in).
3. Remove the 2 bolts and LH floor 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 lb-in).
7. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 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 (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams
C1064
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 694
C107
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 695
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 (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 696
Engine Temperature Sensor: Service and Repair
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Removal and Installation
1. Disconnect the battery ground cable. 2. Remove the intake manifold. 3. Disconnect the cylinder
head temperature (CHT) sensor electrical connector. 4. Remove and discard the CHT sensor.
- To install, tighten to 26 Nm 19 lb-ft).
5. To install, reverse the removal procedure.
- Do not reuse the CHT sensor. Install a new sensor.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Locations > Deactivator Switch
Brake Switch (Cruise Control): Locations Deactivator Switch
View 151-1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Locations > Deactivator Switch > Page 702
View 151-4
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Locations > Deactivator Switch > Page 703
Brake Switch (Cruise Control): Locations Brake Pedal Position Switch
View 151-1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Locations > Deactivator Switch > Page 704
View 151-4
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Diagrams > Deactivator Switch > Page 707
C278
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Diagrams > Page 708
Brake Switch (Cruise Control): Description and Operation
Brake Pedal Position (BPP) Switch
Typical BPP Switch
The BPP switch is sometimes referred to as the 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 antilock 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.
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 (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Diagrams > Page 709
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Locations
Oil Pressure Sender: Locations
View 151-1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Locations > Page 717
View 151-9
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Locations > Page 718
C103
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch
HVAC > Component Information > Locations
Ambient Temperature Sensor / Switch HVAC: Locations
View 151-2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch
HVAC > Component Information > Locations > Page 726
View 151-5
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch
HVAC > Component Information > Locations > Page 727
C132
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch
HVAC > Component Information > Locations > Page 728
Temperature Sensor - Ambient
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch
HVAC > Component Information > Locations > Page 729
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 (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component
Information > Locations
View 151-39
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component
Information > Locations > Page 733
C271
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component
Information > Locations > Page 734
Blower Motor Switch: Description and Operation
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component
Information > Locations > Page 735
Switch - Blower Motor, Front Auxiliary
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component
Information > Locations > Page 736
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 (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch >
Component Information > Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch >
Component Information > Locations > Page 740
C233
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch >
Component Information > Locations > Page 741
Temperature Sensor - In-Vehicle
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch >
Component Information > Locations > Page 742
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Locations
Refrigerant Pressure Sensor / Switch: Locations
View 151-2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Locations > Page 749
View 151-5
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Diagrams > A/C Clutch Cycling Pressure Switch
C130
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Diagrams > A/C Clutch Cycling Pressure Switch > Page 752
C1078
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Description and Operation > A/C Cycling Switch
Refrigerant Pressure Sensor / Switch: Description and Operation A/C Cycling Switch
A/C CYCLING SWITCH
The A/C cycling switch is used to prevent icing of the evaporator core by cycling OFF the A/C
compressor clutch when the suction pressure in the low-pressure side of the refrigerant system
drops below acceptable levels. When the A/C cycling switch circuit is open, the PCM will disengage
the A/C compressor clutch.
The A/C cycling switch is installed on a Schrader-type valve core fitting on the suction accumulator.
It is not necessary to recover the refrigerant before removing the A/C cycling switch.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 755
Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning (A/C) Cycling
Switch
Air Conditioning (A/C) Cycling Switch
The A/C cycling switch may be wired to either the ACCS or ACPSW PCM input. When the A/C
cycling switch opens, the PCM turns off the A/C clutch. For information on the specific function of
the A/C cycling switch, refer to Heating and Air Conditioning, Climate Control System Air
Conditioning System Overview. Also, refer to the applicable Vehicle/Diagrams for vehicle specific
wiring.
If the ACCS signal is not received by the PCM, the PCM circuit will not allow the A/C to operate.
Some applications do not have a dedicated (separate) input to the PCM indicating that A/C is
requested. This information is received by the PCM through the communication link.
Air Conditioning (A/C) High Pressure Switch
The A/C high pressure switch is used for additional A/C system pressure control. The A/C high
pressure switch is either dual function for multiple speed, relay controlled electric fan applications,
or single function for all others.
For refrigerant containment control, the normally closed high pressure contacts open at a
predetermined A/C pressure. This results in the A/C turning off, preventing the A/C pressure from
rising to a level that would open the A/C high pressure relief valve.
For fan control, the normally open medium pressure contacts close at a predetermined A/C
pressure. This grounds the ACPSW circuit input to the PCM. The PCM then turns on the high
speed fan to help reduce the pressure.
For additional information, refer to Heating and Air Conditioning, Climate Control System, Air
Conditioning System Overview or Vehicle/Diagrams.
Air Conditioning Pressure (ACP) Transducer Sensor
A/C Pressure Transducer Sensor Output Voltage
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 756
Typical ACP Transducer Sensor
The ACP transducer sensor is located in the high pressure (discharge) side of the A/C system. The
ACP transducer sensor provides a voltage signal to the PCM that is proportional to the A/C
pressure. The PCM uses this information for A/C clutch control, fan control and idle speed control.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component
Information > Locations
View 151-13
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component
Information > Locations > Page 760
C286
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch >
Component Information > Service and Repair
Dimmer Switch: Service and Repair
INSTRUMENT PANEL DIMMER SWITCH
1. Remove the driver side register. 2. Remove the headlamp switch and bezel as an assembly.
- Disconnect the electrical connectors.
3. Release the 2 tabs and remove the instrument panel dimmer switch.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch >
Component Information > Service and Repair > Page 765
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Locations > Liftgate Glass Ajar Switch
View 151-35
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Locations > Liftgate Glass Ajar Switch > Page 770
Door Switch: Locations Door Ajar Switch
View 151-31
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Locations > Liftgate Glass Ajar Switch > Page 771
View 151-32
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Locations > Liftgate Glass Ajar Switch > Page 772
View 151-34
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Locations > Liftgate Glass Ajar Switch > Page 773
View 151-33
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Diagrams > Liftgate Glass Ajar Switch
C478
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Diagrams > Liftgate Glass Ajar Switch > Page 776
Door Switch: Diagrams Door Ajar Switch
C526
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Diagrams > Liftgate Glass Ajar Switch > Page 777
C602
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Diagrams > Liftgate Glass Ajar Switch > Page 778
C715
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Diagrams > Liftgate Glass Ajar Switch > Page 779
C820
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Service and Repair > Door Ajar Switch - Front Door
Door Switch: Service and Repair Door Ajar Switch - Front Door
DOOR AJAR SWITCH - FRONT DOOR
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Service and Repair > Door Ajar Switch - Front Door > Page 782
Part 2
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 (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Service and Repair > Door Ajar Switch - Front Door > Page 783
Door Switch: Service and Repair Door Ajar Switch - Liftgate
DOOR AJAR SWITCH - LIFTGATE
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Service and Repair > Door Ajar Switch - Front Door > Page 784
Part 2
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 (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Service and Repair > Door Ajar Switch - Front Door > Page 785
Door Switch: Service and Repair Door Ajar Switch - Liftgate Glass
DOOR AJAR SWITCH - LIFTGATE GLASS
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Service and Repair > Door Ajar Switch - Front Door > Page 786
Part 2
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 (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Service and Repair > Door Ajar Switch - Front Door > Page 787
Door Switch: Service and Repair Door Ajar Switch - Rear Door
DOOR AJAR SWITCH - REAR DOOR
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Service and Repair > Door Ajar Switch - Front Door > Page 788
Part 2
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 (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Diagrams
Fuel Gauge Sender: Diagrams
C434A
C434B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Diagrams > Page 792
Fuel Gauge Sender: Description and Operation
Fuel Pump (FP) Module
Typical Electronic Returnless Fuel Pump (FP) Module
Typical Mechanical Returnless Fuel Pump (FP) Module
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Diagrams > Page 793
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 (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Diagrams > Page 794
Fuel Gauge Sender: Service and Repair
FUEL LEVEL SENDER
Removal
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working
on or near any fuel-related component. Highly flammable mixtures are always present and may be
ignited. Failure to follow these instructions may result in serious personal injury.
1. Remove the fuel pump. 2. Remove the screw and the fuel level sender cover.
3. NOTE: Note the routing of the fuel level sender wire for installation.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Diagrams > Page 795
Remove the heat shrink tube covering the fuel level sender wire electrical connector.
4. Disconnect the fuel level sender wire electrical connector.
5. NOTE: Note the routing of the fuel level sender ground wire for installation.
Disconnect the ground wire and remove the screw and lift up to remove the fuel level sender.
Installation
1. Route the fuel level sender ground wire along the fuel pump body.
2. Route the fuel level sender wire through the center of the fuel pump.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Diagrams > Page 796
3. NOTE: Both fuel gauge sending wires must be routed behind the metal sending unit plate.
Hook the fuel level sender on the fuel pump and install and tighten the screw. Connect the fuel
level sender unit ground wire.
4. Slide the heat shrink tube onto the wire harness and connect the fuel level sender wire electrical
connector.
5. WARNING: Do not use an open flame to shrink the heat shrink tube. Use a heat gun only. Fuel
residue may be ignited if an open flame is
used. Failure to follow this instruction may result in serious personal injury.
Using a heat gun, shrink the heat shrink tube.
6. Install the fuel level sender cover and screw and tighten the screw. 7. Install the fuel pump.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning
Switch > Component Information > Locations
Parking Brake Warning Switch: Locations
View 151-18
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning
Switch > Component Information > Locations > Page 800
View 151-19
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning
Switch > Component Information > Locations > Page 801
C2015
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Locations
View 151-13
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Locations > Page 806
C286
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Locations > Page 807
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 (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations
Backup Lamp Switch: Locations
View 151-7
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations > Page 811
View 151-11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations > Page 812
C167
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations
Brake Light Switch: Locations
View 151-1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 816
View 151-4
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 817
C278
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 818
Brake Light Switch: Description and Operation
BRAKE PEDAL POSITION (BPP) SWITCH
Typical BPP Switch
The BPP switch is sometimes referred to as the 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 antilock 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 (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 819
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 (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Liftgate Glass Ajar Switch
View 151-35
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Liftgate Glass Ajar Switch > Page 824
Door Switch: Locations Door Ajar Switch
View 151-31
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Liftgate Glass Ajar Switch > Page 825
View 151-32
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Liftgate Glass Ajar Switch > Page 826
View 151-34
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Liftgate Glass Ajar Switch > Page 827
View 151-33
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Diagrams > Liftgate Glass Ajar Switch
C478
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 830
Door Switch: Diagrams Door Ajar Switch
C526
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 831
C602
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 832
C715
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 833
C820
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Service and Repair > Door Ajar Switch - Front Door
Door Switch: Service and Repair Door Ajar Switch - Front Door
DOOR AJAR SWITCH - FRONT DOOR
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 836
Part 2
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 (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 837
Door Switch: Service and Repair Door Ajar Switch - Liftgate
DOOR AJAR SWITCH - LIFTGATE
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 838
Part 2
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 (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 839
Door Switch: Service and Repair Door Ajar Switch - Liftgate Glass
DOOR AJAR SWITCH - LIFTGATE GLASS
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 840
Part 2
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 (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 841
Door Switch: Service and Repair Door Ajar Switch - Rear Door
DOOR AJAR SWITCH - REAR DOOR
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 842
Part 2
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 (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Locations > Illumination Dimmer Switch
View 151-13
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Locations > Illumination Dimmer Switch > Page 847
Headlamp Dimmer Switch: Locations Multifunction Switch
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Locations > Illumination Dimmer Switch > Page 848
View 151-15
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Diagrams > Multifunction Switch > Page 851
C2298
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Testing and Inspection > Multifunction Switch
Headlamp Dimmer Switch: Testing and Inspection Multifunction Switch
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 854
Headlamp Dimmer Switch: Testing and Inspection Illumination Dimmer Switch
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 855
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Testing and Inspection > Page 856
Headlamp Dimmer Switch: Service and Repair
Steering Column Multifunction Switch
NOTE: Steering wheel removed for clarity.
Steering Column Multifunction Switch (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Testing and Inspection > Page 857
Steering Column Multifunction Switch (Part 2)
Removal and Installation
CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or
damage to the column may result.
1. Disconnect the battery ground cable. 2. Remove the 2 screws and the steering column opening
cover. 3. Remove the 3 screws and the upper and lower steering column shrouds. 4. Disconnect
the multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the
multi-function switch.
^ To install, tighten to 3 Nm (27 lb-inch).
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations
View 151-13
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Page 861
C205
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Page 862
Headlamp Switch: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Page 863
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Page 864
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.
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Component Information > Locations
Turn Signal Switch: Locations
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C202
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Turn Signal Switch: Testing and Inspection
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Turn Signal Switch: Service and Repair
Steering Column Multifunction Switch
NOTE: Steering wheel removed for clarity.
Steering Column Multifunction Switch (Part 1)
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Steering Column Multifunction Switch (Part 2)
Removal and Installation
CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or
damage to the column may result.
1. Disconnect the battery ground cable. 2. Remove the 2 screws and the steering column opening
cover. 3. Remove the 3 screws and the upper and lower steering column shrouds. 4. Disconnect
the multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the
multi-function switch.
^ To install, tighten to 3 Nm (27 lb-inch).
6. To install, reverse the removal procedure.
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Page 881
C2040
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Page 882
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
amount of torque requested by the operator. Depending on the application either a 2-track or
3-track APP sensor is used.
2-Track APP Sensor
2-Track APP Sensor
There are 2 pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive
slope (increasing angle, increasing voltage), but are offset and increase at different rates. The 2
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. If a concern is present with one of the circuits the other input is used. There are 2
reference voltage circuits, 2 signal return circuits, and 2 signal circuits (a total of 6 circuits and pins)
between the PCM and the APP sensor assembly. The reference voltage circuits and the signal
return circuits are shared with the reference voltage circuit and signal return circuit used by the
electronic throttle body (ETB) throttle position sensor. The pedal position signal is converted 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.
3-Track APP Sensor
Typical 3-Track APP Sensor
There are 3 pedal position signals in the sensor. Signal 1, APP1, has a negative slope (increasing
angle, decreasing voltage) and signals 2 and 3, 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. 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. If a concern is present with one of the circuits
the other inputs are used. The pedal position signal is converted 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. There are 2 reference voltage circuits, 2 signal return circuits, and 3 signal
circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. The
reference voltage circuits and the signal return circuits are shared with the reference voltage circuit
and signal return circuit used by the electronic throttle body (ETB) throttle position sensor.
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Air Flow Meter/Sensor: Locations
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C1454
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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
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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.
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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 sensor.
- To install, tighten to 2 Nm (18 lb-in).
3. To install, reverse the removal procedure.
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Position Sensor 1 > Page 895
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Position Sensor
C180
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Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft
Position Sensor > Page 899
C1366
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C1367
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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.
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Camshaft Position Sensor: Service and Repair
CAMSHAFT POSITION (CMP) SENSOR
Removal and Installation
RH side
1. Remove the air cleaner (ACL) outlet pipe.
Both sides
2. Disconnect the camshaft position (CMP) sensor electrical connector. 3. Remove the bolt and the
CMP sensor.
- To install, tighten to 10 Nm (89 lb-in).
4. To install, reverse the removal procedure.
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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.
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C1064
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Crankshaft Position Sensor: Locations
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913
Crankshaft Position Sensor: Diagrams
C101
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C1120
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915
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 decelerations between teeth.
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916
Crankshaft Position Sensor: Service and Repair
CRANKSHAFT POSITION (CKP) SENSOR
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917
Removal and Installation
1. With vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt. 3.
Disconnect the A/C compressor coil electrical connector. 4. Detach the battery cable retainer from
the A/C compressor stud bolts. 5. Remove the nut and detach the A/C tube bracket.
- To install, tighten to 10 Nm (89 lb-in).
6. Remove the stud bolts and position the A/C compressor aside.
- To install, tighten to 25 Nm (18 lb-ft).
7. Disconnect the crankshaft position (CKP) sensor electrical connector. 8. Remove the bolt and
the CKP sensor.
- To install, tighten to 10 Nm (89 lb-in).
9. To install, reverse the removal procedure.
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921
C107
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922
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.
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923
Engine Temperature Sensor: Service and Repair
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Removal and Installation
1. Disconnect the battery ground cable. 2. Remove the intake manifold. 3. Disconnect the cylinder
head temperature (CHT) sensor electrical connector. 4. Remove and discard the CHT sensor.
- To install, tighten to 26 Nm 19 lb-ft).
5. To install, reverse the removal procedure.
- Do not reuse the CHT sensor. Install a new sensor.
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Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation
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.
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Page 927
Fuel Level Sensor: Service and Repair
FUEL LEVEL SENDER
Removal
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working
on or near any fuel-related component. Highly flammable mixtures are always present and may be
ignited. Failure to follow these instructions may result in serious personal injury.
1. Remove the fuel pump. 2. Remove the screw and the fuel level sender cover.
3. NOTE: Note the routing of the fuel level sender wire for installation.
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Page 928
Remove the heat shrink tube covering the fuel level sender wire electrical connector.
4. Disconnect the fuel level sender wire electrical connector.
5. NOTE: Note the routing of the fuel level sender ground wire for installation.
Disconnect the ground wire and remove the screw and lift up to remove the fuel level sender.
Installation
1. Route the fuel level sender ground wire along the fuel pump body.
2. Route the fuel level sender wire through the center of the fuel pump.
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Page 929
3. NOTE: Both fuel gauge sending wires must be routed behind the metal sending unit plate.
Hook the fuel level sender on the fuel pump and install and tighten the screw. Connect the fuel
level sender unit ground wire.
4. Slide the heat shrink tube onto the wire harness and connect the fuel level sender wire electrical
connector.
5. WARNING: Do not use an open flame to shrink the heat shrink tube. Use a heat gun only. Fuel
residue may be ignited if an open flame is
used. Failure to follow this instruction may result in serious personal injury.
Using a heat gun, shrink the heat shrink tube.
6. Install the fuel level sender cover and screw and tighten the screw. 7. Install the fuel pump.
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Fuel Tank Pressure Sensor: Locations
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C435
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935
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.
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936
Fuel Tank Pressure Sensor: Service and Repair
FUEL TANK PRESSURE SENSOR
Removal and Installation
WARNING:
- When working on or near the evaporative emission (EVAP) system, disconnect the battery ground
cable from the battery. The EVAP system contains fuel vapor and condensed fuel vapor, so an
electrical spark may cause a fire or explosion. Failure to follow this instruction may result in serious
personal injury.
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious personal injury.
1. Remove the evaporative emission (EVAP) canister. 2. Remove the fuel tank shield from the fuel
tank.
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3. Disconnect the fuel tank pressure (FTP) sensor electrical connector. 4. Disconnect the 3 FTP
sensor and tube assembly quick connect couplings from the fuel pump module and the vapor vent
valves. 5. Remove the FTP sensor and tube assembly. 6. To install, reverse the removal
procedure. 7. Leak test the EVAP system. 8. Carry out the evaporative emission repair verification
drive cycle.
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Intake Air Temperature Sensor: Locations
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941
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942
C1454
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943
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
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944
fuel, spark, and air flow.
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 above. 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.
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
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Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page
945
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.
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Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 950
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.
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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.
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Page 957
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Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations >
Page 958
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.
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Page 959
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.
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen
Sensor (HO2S) #11
Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #11
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen
Sensor (HO2S) #11 > Page 964
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Sensor (HO2S) #11 > Page 965
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen
Sensor (HO2S) #11 > Page 966
Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #21
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Sensor (HO2S) #11 > Page 967
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Sensor (HO2S) #11 > Page 968
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Sensor (HO2S) #11 > Page 969
Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #22
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Sensor (HO2S) #11 > Page 970
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Sensor (HO2S) #11 > Page 971
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Sensor (HO2S) #22
C141
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen
Sensor (HO2S) #22 > Page 974
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Sensor (HO2S) #22 > Page 976
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 977
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.
Universal HO2S
The universal HO2S, sometimes referred to as a wideband oxygen sensor, uses the typical HO2S
combined with a current controller in the PCM to infer an air/fuel ratio relative to the stoichiometric
air/fuel ratio. This is accomplished by balancing the amount of oxygen ions pumped in or out of a
measurement chamber within the sensor. The typical HO2S within the universal HO2S is used to
detect the oxygen content of the exhaust gas in the measurement chamber. The oxygen content
inside the measurement chamber is maintained at the stoichiometric air/fuel ratio by pumping
oxygen ions in and out of the measurement chamber. As the exhaust gasses get richer or leaner,
the amount of oxygen that must be pumped in or out to maintain a stoichiometric air/fuel ratio in the
measurement chamber varies in proportion to the air/fuel ratio. The amount of current required to
pump the oxygen ions in or out of the measurement chamber is used to measure the air/fuel ratio.
The measured air/fuel ratio is actually the output from the current controller in the PCM and not a
signal that comes directly from the sensor.
The universal HO2S also uses a self-contained reference chamber to make sure an oxygen
differential is always present. The oxygen for the reference chamber is supplied by pumping small
amounts of oxygen ions from the measurement chamber into the reference chamber. The universal
HO2S does not need access to outside air.
Part to part variance is compensated for by placing a resistor in the connector. This resistor is used
to trim the current measured by the current controller in the PCM.
Embedded with the sensing element is the universal H02S heater. The heater allows the engine to
enter closed loop operation sooner. The heating element heats the sensor to a temperature of
780°C (1,436°F). The VPWR circuit supplies voltage to the heater. The PCM controls the heater on
and off by providing the ground to maintain the sensor at the correct temperature for maximum
accuracy.
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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)
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor (HO2S) > Page 980
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.
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor (HO2S) > Page 981
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.
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor (HO2S) > Page 982
Oxygen Sensor: Service and Repair Catalyst Monitor Sensor
CATALYST MONITOR SENSOR
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor (HO2S) > Page 983
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.
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Oxygen Sensor (HO2S) > Page 984
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.
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Page 988
C121
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Page 989
Power Steering Pressure Switch: Description and Operation
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.
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.
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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
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Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Description and Operation > Page 993
The tube mounted differential pressure feedback EGR sensor is identical in operation as the larger
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.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations
Throttle Position Sensor: Locations
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C189
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 999
Throttle Position Sensor: Description and Operation
Electronic Throttle Body (ETB) Throttle Position Sensor
The ETB throttle position sensor has 2 signal circuits in the sensor for redundancy. The redundant
ETB throttle position signals are required for increased monitoring. The first ETB throttle 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). The 2 ETB throttle 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. The reference voltage circuit
and the signal return circuit is shared with the reference voltage circuits and signal return circuits
used by the APP 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
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1000
Throttle Position Sensor: Service and Repair
THROTTLE POSITION (TP) SENSOR
Heated PCV Fitting
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Throttle Position (TP) Sensor
Removal
Vehicles equipped with a 4.6L (3V) engine 1. Remove the air cleaner (ACL) outlet pipe. 2. Remove
the bolts and position the heated 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 throttle position (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.
Installation
All vehicles
1. CAUTION:
- Do not reuse the throttle position (TP) sensor and screws. A new TP sensor and screws must be
installed. Failure to follow this instruction may result in poor engine performance.
- Do not use a high-speed driver to install the new screws or damage to the throttle position (TP)
sensor may 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.
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1002
- 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 ACL outlet pipe.
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Locations
Transmission Position Switch/Sensor: Locations
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Locations > Page 1006
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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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
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Diagrams > Diagram Information and Instructions > Page 1009
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
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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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
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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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
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Symbols (Part 2)
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Diagrams > Diagram Information and Instructions > Page 1013
Symbols (Part 3)
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Diagrams > Diagram Information and Instructions > Page 1014
Symbols (Part 4)
Symbols (Part 5)
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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 terminal by pulling each wire at the end of the connector.
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Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
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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
3 = Splice tape
4 = Harness tape
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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.
3. lnstall 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 seat wire splice.
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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.
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 6.35mm (1/4 in) 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.
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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.
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, barrel squeeze tool handles appropriate 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.
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The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
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C167
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Transmission Position Switch/Sensor: Adjustments
Transmission Range (TR) Sensor Adjustment - 5R55S
Adjust
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever 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 digital transmission range (TR) sensor electrical
connector.
4. Disconnect the digital TR sensor electrical connector.
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5. Remove the selector lever cable end from the manual control lever.
6. Remove the outer manual control lever nut and the 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 lb-inch).
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9. Install the outer manual lever and nut.
^ Tighten to 48 Nm (35 lb-ft).
10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable
bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable
to make sure that it is locked into the selector lever cable 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 selector lever cable end is correctly installed.
Install the selector lever cable end onto the manual control lever.
11. Reconnect the digital TR sensor electrical connector.
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12. Move the rubber boot back over the TR electrical connector.
13. NOTE: If the selector lever cable shield is loose on the selector lever cable, replace the selector
lever cable shield.
Install the selector lever cable shield.
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.
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Transmission Position Switch/Sensor: Service and Repair
Digital Transmission Range (TR) Sensor - 5R55S
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by
prying on the side of the selector lever cable shield closest to the boot, then sliding the selector
lever
cable shield away from the boot.
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3. Move the rubber boot back to gain access to the digital transmission range (TR) sensor electrical
connector.
4. Disconnect the digital TR sensor electrical connector.
5. Remove the selector lever cable from the manual control lever.
6. Remove the outer manual control lever.
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7. Remove the digital TR sensor.
Installation
1. CAUTION: The digital transmission range (TR) 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. ^
Tighten to 8 Nm (71 lb-inch).
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3. Install the outer manual lever.
^ Tighten to 48 Nm (35 lb-ft).
4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen
for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that
it is locked into the selector lever cable 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
selector lever cable end is correctly installed.
Install the selector lever cable to the manual control lever.
5. Connect the digital TR sensor electrical connector.
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6. Move the rubber boot back over the TR sensor electrical connector.
7. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector
lever cable shield.
Install the selector lever cable shield.
8. Verify that the selector lever cable is adjusted correctly.
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Vehicle Speed Sensor: Description and Operation
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.
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.
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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
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and Operation > Page 1039
The tube mounted differential pressure feedback EGR sensor is identical in operation as the larger
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.
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View 151-13
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Page 1044
C2040
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Page 1045
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
amount of torque requested by the operator. Depending on the application either a 2-track or
3-track APP sensor is used.
2-Track APP Sensor
2-Track APP Sensor
There are 2 pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive
slope (increasing angle, increasing voltage), but are offset and increase at different rates. The 2
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. If a concern is present with one of the circuits the other input is used. There are 2
reference voltage circuits, 2 signal return circuits, and 2 signal circuits (a total of 6 circuits and pins)
between the PCM and the APP sensor assembly. The reference voltage circuits and the signal
return circuits are shared with the reference voltage circuit and signal return circuit used by the
electronic throttle body (ETB) throttle position sensor. The pedal position signal is converted 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.
3-Track APP Sensor
Typical 3-Track APP Sensor
There are 3 pedal position signals in the sensor. Signal 1, APP1, has a negative slope (increasing
angle, decreasing voltage) and signals 2 and 3, 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. 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. If a concern is present with one of the circuits
the other inputs are used. The pedal position signal is converted 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. There are 2 reference voltage circuits, 2 signal return circuits, and 3 signal
circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. The
reference voltage circuits and the signal return circuits are shared with the reference voltage circuit
and signal return circuit used by the electronic throttle body (ETB) throttle position sensor.
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Air Flow Meter/Sensor: Locations
View 151-8
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View 151-9
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C1454
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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
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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.
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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 sensor.
- To install, tighten to 2 Nm (18 lb-in).
3. To install, reverse the removal procedure.
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Fuel Pressure Sensor/Switch: Locations
View 151-7
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1057
View 151-9
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1058
C173
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1059
Fuel Pressure Sensor/Switch: 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.
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Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page
1060
Fuel Pressure Sensor/Switch: Service and Repair
FUEL RAIL PRESSURE AND TEMPERATURE SENSOR
Removal and Installation
WARNING:
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious personal injury.
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the
fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under
high pressure, even when the engine is not running. Failure to follow this instruction may result in
serious personal injury.
1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel
rail pressure and temperature sensor electrical connector. 4. Disconnect the fuel rail pressure and
temperature sensor vacuum hose connector. 5. Remove the 2 bolts and the fuel rail pressure and
temperature sensor.
- To install, tighten to 6 Nm (53 lb-in).
6. To install, reverse the removal procedure.
- Inspect the O-ring seal and install a new O-ring seal if necessary.
- Lubricate the O-ring seal with clean engine oil.
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Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations
Fuel Temperature Sensor: Locations
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Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 1064
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Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 1065
C173
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Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 1066
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 (V8-4.6L (2008))
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Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 1067
Fuel Temperature Sensor: Service and Repair
FUEL RAIL PRESSURE AND TEMPERATURE SENSOR
Removal and Installation
WARNING:
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious personal injury.
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the
fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under
high pressure, even when the engine is not running. Failure to follow this instruction may result in
serious personal injury.
1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel
rail pressure and temperature sensor electrical connector. 4. Disconnect the fuel rail pressure and
temperature sensor vacuum hose connector. 5. Remove the 2 bolts and the fuel rail pressure and
temperature sensor.
- To install, tighten to 6 Nm (53 lb-in).
6. To install, reverse the removal procedure.
- Inspect the O-ring seal and install a new O-ring seal if necessary.
- Lubricate the O-ring seal with clean engine oil.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations
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Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 1071
C282
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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 1072
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, Roadside Emergencies for the location of the IFS switch.
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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 1073
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 (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations
Throttle Position Sensor: Locations
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Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 1077
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C189
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Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 1079
Throttle Position Sensor: Description and Operation
Electronic Throttle Body (ETB) Throttle Position Sensor
The ETB throttle position sensor has 2 signal circuits in the sensor for redundancy. The redundant
ETB throttle position signals are required for increased monitoring. The first ETB throttle 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). The 2 ETB throttle 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. The reference voltage circuit
and the signal return circuit is shared with the reference voltage circuits and signal return circuits
used by the APP 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
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Throttle Position Sensor: Service and Repair
THROTTLE POSITION (TP) SENSOR
Heated PCV Fitting
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Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 1081
Throttle Position (TP) Sensor
Removal
Vehicles equipped with a 4.6L (3V) engine 1. Remove the air cleaner (ACL) outlet pipe. 2. Remove
the bolts and position the heated 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 throttle position (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.
Installation
All vehicles
1. CAUTION:
- Do not reuse the throttle position (TP) sensor and screws. A new TP sensor and screws must be
installed. Failure to follow this instruction may result in poor engine performance.
- Do not use a high-speed driver to install the new screws or damage to the throttle position (TP)
sensor may 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.
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Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 1082
- 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 ACL outlet pipe.
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Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor
1
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Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor
1 > Page 1088
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Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor
1 > Page 1089
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Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor
> Page 1092
C1366
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Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor
> Page 1093
C1367
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 1094
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.
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Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 1095
Camshaft Position Sensor: Service and Repair
CAMSHAFT POSITION (CMP) SENSOR
Removal and Installation
RH side
1. Remove the air cleaner (ACL) outlet pipe.
Both sides
2. Disconnect the camshaft position (CMP) sensor electrical connector. 3. Remove the bolt and the
CMP sensor.
- To install, tighten to 10 Nm (89 lb-in).
4. To install, reverse the removal procedure.
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Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations
Crankshaft Position Sensor: Locations
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Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1099
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Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1100
Crankshaft Position Sensor: Diagrams
C101
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Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1102
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 decelerations between teeth.
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Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1103
Crankshaft Position Sensor: Service and Repair
CRANKSHAFT POSITION (CKP) SENSOR
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Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1104
Removal and Installation
1. With vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt. 3.
Disconnect the A/C compressor coil electrical connector. 4. Detach the battery cable retainer from
the A/C compressor stud bolts. 5. Remove the nut and detach the A/C tube bracket.
- To install, tighten to 10 Nm (89 lb-in).
6. Remove the stud bolts and position the A/C compressor aside.
- To install, tighten to 25 Nm (18 lb-ft).
7. Disconnect the crankshaft position (CKP) sensor electrical connector. 8. Remove the bolt and
the CKP sensor.
- To install, tighten to 10 Nm (89 lb-in).
9. To install, reverse the removal procedure.
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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
Part 1
Part 2
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.
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Switches - Ignition System > Knock Sensor > Component Information > Locations
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Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1112
C108
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1113
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.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Forward Crash Sensor
Impact Sensor: Locations Forward Crash Sensor
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Component Information > Locations > Forward Crash Sensor > Page 1119
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Component Information > Locations > Forward Crash Sensor > Page 1120
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Component Information > Locations > Forward Crash Sensor > Page 1121
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Component Information > Locations > Forward Crash Sensor > Page 1122
Impact Sensor: Locations Side Impact Sensor
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Component Information > Locations > Forward Crash Sensor > Page 1123
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Component Information > Locations > Forward Crash Sensor > Page 1124
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Component Information > Diagrams > Forward Crash Sensor
Impact Sensor: Diagrams Forward Crash Sensor
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Component Information > Diagrams > Forward Crash Sensor > Page 1130
Impact Sensor: Diagrams Side Impact Sensor
C567A
C644A
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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
Removal and Installation
WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the
impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting
areas to the original production configuration. A new RCM and sensors must be installed whether
or not the air bags have deployed. Failure to follow these instructions may result in serious
personal injury or death in a crash.
NOTE:
- The air bag warning indicator 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.
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Component Information > Service and Repair > Front Impact Severity Sensor > Page 1134
- 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 SRS. 2. Remove the 4 pin-type retainers and the lower radiator air deflector. 3.
Disconnect the electrical connector.
4. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact
sensor (if equipped) to the specified torque.
Failure to do so may result in incorrect restraint system operation, which increases the risk of
personal injury or death in a crash.
NOTE: Make sure the radiator support and front impact severity sensor mating surfaces are clean
and free of foreign material.
Remove the bolt and sensor. To install, tighten to 12 Nm (9 lb-ft).
5. To install, reverse the removal procedure. 6. Repower the SRS.
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Component Information > Service and Repair > Front Impact Severity Sensor > Page 1135
Impact Sensor: Service and Repair Side Impact Sensor - C-Pillar
SIDE IMPACT SENSOR - C-PILLAR
Removal and Installation
WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the
impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting
areas to the original production configuration. A new RCM and sensors must be installed whether
or not the air bags have deployed. Failure to follow these instructions may result in serious
personal injury or death in a crash.
NOTE:
- The air bag warning indicator 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.
- The LH and RH C-pillar mounted side impact sensors are not interchangeable.
1. Depower the SRS. 2. Remove the rear door scuff plate.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Front Impact Severity Sensor > Page 1136
3. Remove the bolt and 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 electrical connector.
7. 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 side impact sensor. To install, tighten to 12 Nm (9 lb-ft).
8. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact
sensor (if equipped) to the specified torque.
Failure to do so may result in incorrect restraint system operation, which increases the risk of
personal injury or death in a crash.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
To install, reverse the removal procedure.
9. Repower the SRS.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Front Impact Severity Sensor > Page 1137
Impact Sensor: Service and Repair Side Impact Sensor - Front Door
SIDE IMPACT SENSOR - FRONT DOOR
Removal and Installation
WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the
impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting
areas to the original production configuration. A new RCM and sensors must be installed whether
or not the air bags have deployed. Failure to follow these instructions may result in serious
personal injury or death in a crash.
NOTE:
- The air bag warning indicator 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.
- Driver side shown, passenger side similar.
1. Depower the SRS. 2. Remove the front interior door trim panel. 3. Detach the rearward lower
corner of the weathershield on the door to expose the side impact sensor. 4. Disconnect the side
impact sensor electrical connector.
5. 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Front Impact Severity Sensor > Page 1138
Remove the bolt and the side impact sensor. To install, tighten to 9 Nm (80 lb-in).
6. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact
sensor (if equipped) to the specified torque.
Failure to do so may result in incorrect restraint system operation, which increases the risk of
personal injury or death in a crash.
To install, reverse the removal procedure.
7. Repower the SRS.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Locations > Safety Belt Buckle Switch, Passenger
View 151-29
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Locations > Safety Belt Buckle Switch, Passenger > Page 1143
View 151-28
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Diagrams > Safety Belt Buckle Switch, Driver > Page 1146
C3066
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Locations > Seat Pressure Sensor, Left
View 151-29
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Locations > Seat Pressure Sensor, Left > Page 1151
View 151-29
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Diagrams > Seat Pressure Sensor, Left
C3291
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Diagrams > Seat Pressure Sensor, Left > Page 1154
C3292
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Diagrams > Page 1155
Seat Occupant Sensor: Description and Operation
OCCUPANT CLASSIFICATION SENSOR (OCS) SYSTEM
The occupant classification sensor (OCS) system is standard equipment on all front passenger
seats. For information on diagnosing or servicing the OCS system, refer to Air Bag Systems.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Diagrams > Page 1156
Seat Occupant Sensor: Service and Repair
OCCUPANT CLASSIFICATION SENSOR
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Diagrams > Page 1157
Part 2
Removal
WARNING:
- The occupant classification sensor (OCS) rails have a built-in strain gauge which may operate
incorrectly if an OCS rail is dropped by itself, dropped after it is installed to the front passenger seat
or dropped after it is installed to a front passenger seat track assembly. Use care when handling an
OCS rail before or after it is installed to the front passenger seat or seat track assembly. Failure to
follow these instructions may result in incorrect operation of the OCS system and increases the risk
of serious personal injury or death in a crash.
- Do not disassemble the occupant classification sensor (OCS) rail or tighten or loosen any of the
nuts and bolts installed to the OCS rail body. Only the 8 bolts that attach the 2 OCS rails to the seat
track may be removed and installed. Failure to follow these instructions may result in incorrect
operation of the OCS system and increase the risk of serious personal injury or death in a crash.
- Never allow oil, grease, water or foreign contaminants to get on/in the occupant classification
sensor (OCS) components or electrical connectors. Failure to follow this instruction may result in
incorrect operation of the OCS system and increases the risk of serious personal injury or death in
a crash.
- Use care when handling the front passenger seat and track assembly. Dropping the assembly,
placing excessive weight on or sitting on a front passenger seat that is not secured in the vehicle
may result in damaged seat components. Failure to follow these instructions may result in incorrect
operation of the occupant classification sensor (OCS) system and increases the risk of serious
personal injury or death in a crash.
CAUTION: Prevent oil and/or grease from getting on the occupant classification sensor (OCS) rail
bolts as this can lead to tightening beyond the specified torque value. Failure to follow this
instruction may result in damaged or broken OCS rail bolts.
NOTE:
- The air bag warning indicator 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 shown, inboard similar.
1. Remove the passenger seat.
2. CAUTION: Before releasing the occupant classification sensor (OCS) rail electrical connector,
push only on the tip of the connector
release tab to release the electrical connector. Do not insert the tool too deep into the OCS rail
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Diagrams > Page 1158
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. 6. Move the seat to the rearward most
position.
- If equipped with a power seat track, apply power and ground to the pins shown.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Diagrams > Page 1159
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.
- To make sure of correct installation, the OCS rail bolts must be installed in the sequence shown.
1. WARNING: To prevent foreign material and contaminants from entering the occupant
classification sensor (OCS) rail, make sure the
OCS rail shield is present, is not damaged and is correctly installed to the OCS rail. Failure to
follow these instructions may result in incorrect operation of the OCS system and increases the risk
of serious personal injury or death in a crash.
CAUTION: Prevent oil and/or grease from getting on the OCS rail bolts as this can lead to
tightening beyond the specified torque value. Failure to follow this instruction may result in
damaged or broken OCS rail bolts.
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. 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).
3. While still holding the OCS rail and shield firmly in position, install the OCS rail front mounting
position front bolt.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Diagrams > Page 1160
- 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 frame.
- 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. 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, 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, carry out the Occupant Classification Sensor (OCS) System
Reset procedure and prove out the SRS. See: Restraint Systems/Air Bag Systems/Service and
Repair/Occupant Classification Sensor (OCS) System Reset
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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:
- Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive
load limiting retractors. Failure to follow this instruction may result in the accidental deployment of
the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious
personal injury or death.
- Never probe the electrical connectors on air bag, safety canopy or side air curtain modules.
Failure to follow this instruction may result in the accidental deployment of these modules, which
increases the risk of serious personal injury or death.
NOTE:
- The air bag warning indicator 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 seat similar.
1. Position the front seat to the rearmost and upward position. 2. Depower the SRS. 3. Disconnect
the electrical connector.
4. WARNING: Always tighten the seat position sensor retaining bolt to specified torque. Failure to
do so may result in incorrect restraint
system operation, which increases the risk of personal injury or death in a crash.
NOTE: Note the position of the seat position sensor locating tab for installation.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor >
Component Information > Service and Repair > Page 1164
Remove the bolt and seat position sensor. To install, tighten to 6 Nm (53 lb-in).
5. To install, reverse the removal procedure. 6. Repower the SRS.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Locations
View 151-28
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Locations > Page 1168
C356
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Part 1
Part 2
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 (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations
Neutral Safety Switch: Locations
View 151-7
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations > Page 1177
View 151-11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations > Page 1178
C167
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 1184
C121
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 1185
Power Steering Pressure Switch: Description and Operation
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.
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 (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Locations
Steering Angle Sensor: Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 1189
View 151-15
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 1190
C226
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Locations
Steering Angle Sensor: Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 1195
View 151-15
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 1196
C226
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Monitoring System (TPMS) Sensor Training
Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor
Training
Tire Pressure Monitoring System (TPMS) Sensor Training
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). For additional information, refer to
Tire Pressure Monitoring System (TPMS) Sensor Activation.
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 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 activation tool, attempt to activate the same sensor with
the activation tool. If the sensor still does not respond, move the vehicle to rotate the wheels at
least 1/4 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. NOTE: 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.
6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the
activation tool must remain in place 180 degrees from
the valve stem.
Place the activation tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press
and release the test button on the special tool. The horn will sound briefly to indicate that the tire
pressure sensor has been recognized by the SJB.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Monitoring System (TPMS) Sensor Training > Page 1202
7. Within 2 minutes of the horn sounding, place the 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.
8. 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.
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 IDs trained to the SJB and document them
on the applicable warranty claim.
10. 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.
If the sensors are being trained due to the installation of a new SJB, clear any DTCs and perform
the SJB on-demand self test.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Monitoring System (TPMS) Sensor Training > Page 1203
Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor
Activation
Tire Pressure Monitoring System (TPMS) Sensor Activation
NOTE: The tire pressure sensors will go into a "sleep mode" after 30 minutes of inactivity to
conserve battery power. The sensors do not transmit information while in sleep mode, it will be
necessary to wake them up so they will transmit the latest tire pressure information.
1. Turn the ignition switch to the ON position. 2. Position the tire pressure monitor activation tool
against the LF tire sidewall 180 degrees from the tire valve stem.
3. NOTE: The activation tool will provide feedback in the form of a flashing green light and a beep
sound for each successful response from a tire
pressure sensor.
Press the test button on the activation tool to activate the sensor, activate the sensor at least 2
times.
4. Repeat Steps 2 and 3 for the remaining tires. 5. If the tire pressure monitoring system (TPMS)
indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom
Chart
in Diagnosis and Testing.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Disassembly
WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous
chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes,
flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any
part of the battery is swallowed, contact a physician immediately. When disposing of TPMS
sensors, follow the correct procedures for hazardous material disposal. Failure to follow these
instructions may result in serious personal injury.
NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of
accordingly.
NOTE: 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.
1. CAUTION: The sensor, cradle and strap may 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 may occur.
Using a pocket screwdriver or similar tool, remove the sensor locking clip.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1206
3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to
the sensor may 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 may 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 (V8-4.6L (2008))
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 1207
3. CAUTION: The sensor, cradle and strap may 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 (V8-4.6L (2008))
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 1208
Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and
Cradle
Tire Pressure Monitoring System (TPMS) Strap and Cradle
Disassembly
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1209
WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous
chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes,
flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any
part of the battery is swallowed, contact a physician immediately. When disposing of TPMS
sensors, follow the correct procedures for hazardous material disposal. Failure to follow these
instructions may result in serious personal injury.
NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of
accordingly.
NOTE: 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.
1. Remove the tire pressure monitoring system (TPMS) sensor. For additional information, refer to
Tire Pressure Monitoring System (TPMS) Sensor.
2. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this
instruction may result in serious personal injury.
WARNING: Wear protective gloves when handling components or parts that have pointed or sharp
edges. Failure to follow this instruction may result in serious personal injury.
Remove a factory installed strap in the following 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.
3. To remove a dealer installed strap, turn the worm gear screw until the strap is fully released from
the worm gear.
^ Discard the strap.
4. 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 may 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 (V8-4.6L (2008))
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 1210
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 degrees 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 and
sensor are mounted at the lowest spot
possible to avoid damaging the sensor during wheel and tire disassembly and assembly.
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 lb-inch).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1211
6. CAUTION: The sensor, cradle and strap may 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 (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
1218
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
1219
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
1220
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
1221
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
1222
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
1223
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
1224
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
1225
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
1226
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
1227
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
1228
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
1229
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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
1230
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Page 1231
Brake Switch - TCC: Description and Operation
BRAKE PEDAL POSITION (BPP) SWITCH
Typical BPP Switch
The BPP switch is sometimes referred to as the 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 antilock 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 (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1236
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1237
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1238
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1239
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1240
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 1241
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1242
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1243
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1244
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1245
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1246
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1247
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 1248
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1253
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1254
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1255
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1256
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1257
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1258
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1259
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1260
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1261
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1262
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1263
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1264
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 1265
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations
View 151-15
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1271
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1272
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1273
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1274
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1275
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1276
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1277
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1278
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1279
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1280
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1281
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1282
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 1283
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Transmission
Control (TC) Switch > Page 1286
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 (V8-4.6L (2008))
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 1287
Transmission Mode Switch: Service and Repair
Transmission Control (TC) Switch
Transmission Control (TC) Switch
Removal
1. Remove the selector lever knob. 2. Remove the transmission control (TC) switch from the knob.
Installation
1. Install the TC switch into the selector lever knob. 2. Install the selector lever knob.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Transmission Position Switch/Sensor: Locations
View 151-7
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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 > Page 1291
View 151-11
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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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
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Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information
and Instructions > Page 1294
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
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Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information
and Instructions > Page 1295
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
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Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information
and Instructions > Page 1296
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information
and Instructions > Page 1297
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1298
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1299
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information
and Instructions > Page 1300
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 terminal by pulling each wire at the end of the connector.
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Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information
and Instructions > Page 1301
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
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Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information
and Instructions > Page 1302
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
3 = Splice tape
4 = Harness tape
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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 1303
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1304
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1305
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 1306
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1307
C167
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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 1308
Transmission Position Switch/Sensor: Adjustments
Transmission Range (TR) Sensor Adjustment - 5R55S
Adjust
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever 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 digital transmission range (TR) sensor electrical
connector.
4. Disconnect the digital TR sensor electrical connector.
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Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1309
5. Remove the selector lever cable end from the manual control lever.
6. Remove the outer manual control lever nut and the 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 lb-inch).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1310
9. Install the outer manual lever and nut.
^ Tighten to 48 Nm (35 lb-ft).
10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable
bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable
to make sure that it is locked into the selector lever cable 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 selector lever cable end is correctly installed.
Install the selector lever cable end onto the manual control lever.
11. Reconnect the digital TR sensor electrical connector.
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Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1311
12. Move the rubber boot back over the TR electrical connector.
13. NOTE: If the selector lever cable shield is loose on the selector lever cable, replace the selector
lever cable shield.
Install the selector lever cable shield.
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.
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Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1312
Transmission Position Switch/Sensor: Service and Repair
Digital Transmission Range (TR) Sensor - 5R55S
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by
prying on the side of the selector lever cable shield closest to the boot, then sliding the selector
lever
cable shield away from the boot.
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Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1313
3. Move the rubber boot back to gain access to the digital transmission range (TR) sensor electrical
connector.
4. Disconnect the digital TR sensor electrical connector.
5. Remove the selector lever cable from the manual control lever.
6. Remove the outer manual control lever.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1314
7. Remove the digital TR sensor.
Installation
1. CAUTION: The digital transmission range (TR) 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. ^
Tighten to 8 Nm (71 lb-inch).
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Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1315
3. Install the outer manual lever.
^ Tighten to 48 Nm (35 lb-ft).
4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen
for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that
it is locked into the selector lever cable 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
selector lever cable end is correctly installed.
Install the selector lever cable to the manual control lever.
5. Connect the digital TR sensor electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1316
6. Move the rubber boot back over the TR sensor electrical connector.
7. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector
lever cable shield.
Install the selector lever cable shield.
8. Verify that the selector lever cable is adjusted correctly.
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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 151-11
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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 1321
Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor
View 151-7
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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 1322
View 151-11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1323
View 151-11
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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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
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Instructions > Page 1326
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
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Instructions > Page 1327
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
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Instructions > Page 1328
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 1329
Symbols (Part 2)
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 1330
Symbols (Part 3)
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 1331
Symbols (Part 4)
Symbols (Part 5)
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 1332
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 terminal by pulling each wire at the end of the connector.
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 1333
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
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Instructions > Page 1334
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
3 = Splice tape
4 = Harness tape
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Instructions > Page 1335
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.
3. lnstall 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 seat wire splice.
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 1336
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.
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 6.35mm (1/4 in) 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.
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 1337
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.
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, barrel squeeze tool handles appropriate 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.
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 1338
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 1339
Transmission Speed Sensor: Connector Views
C193
C143
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 1340
C164
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft
Speed Sensor - 5R55S
Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor - 5R55S
Intermediate Shaft Speed Sensor
Intermediate Shaft Speed Sensor
Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
Four wheel drive (4WD) vehicles
2. Disconnect the front driveshaft from the transfer case.
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Speed Sensor - 5R55S > Page 1343
3. Disconnect the front driveshaft from the front differential.
4. Remove the front driveshaft from the vehicle.
All vehicles
5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield
closest to the boot, then sliding the selector lever
cable shield away from the boot.
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft
Speed Sensor - 5R55S > Page 1344
6. Remove the selector lever cable and selector lever cable 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.
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft
Speed Sensor - 5R55S > Page 1345
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.
2 Tighten the intermediate shaft speed sensor screw.
^ Tighten to 14 Nm (10 lb-ft).
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 selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable
bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable
to make sure that it is locked into the selector lever cable 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 selector lever cable end is correctly installed.
Install the selector lever cable and selector lever cable bracket. ^
Tighten to 40 Nm (30 lb-ft).
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft
Speed Sensor - 5R55S > Page 1346
4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector
lever cable shield.
Install the selector lever cable shield.
4WD vehicles
5. Install the front driveshaft in the vehicle.
6. Connect the front driveshaft to the transfer case.
^ Tighten to 30 Nm (22 lb-ft).
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft
Speed Sensor - 5R55S > Page 1347
7. Connect the front driveshaft to the front differential.
^ Tighten to 19 Nm (14 lb-ft).
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft
Speed Sensor - 5R55S > Page 1348
Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor - 5R55S
Output Shaft Speed (OSS) Sensor
Output Shaft Speed (OSS) Sensor
Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
Four wheel drive (4WD) vehicles
2. Disconnect the front driveshaft from the transfer case.
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft
Speed Sensor - 5R55S > Page 1349
3. Disconnect the front driveshaft from the front differential.
4. Remove the front driveshaft from the vehicle.
All vehicles
5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield
closest to the boot, then sliding the selector lever
cable shield away from the boot.
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft
Speed Sensor - 5R55S > Page 1350
6. Remove the selector lever cable and selector lever cable bracket.
7. Disconnect the heated oxygen sensor (HO2S) connector from the transmission case.
8. Disconnect the output shaft speed (OSS) sensor electrical connector.
9. Remove the OSS sensor.
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Speed Sensor - 5R55S > Page 1351
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.
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 lb-ft).
2. Connect the OSS sensor electrical connector.
3. Connect the HO2S connector to the transmission case.
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft
Speed Sensor - 5R55S > Page 1352
4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable
bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable
to make sure that it is locked into the selector lever cable 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 selector lever cable end is correctly installed.
Install the selector lever cable and selector lever cable bracket. ^
Tighten to 40 Nm (30 lb-ft).
5. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector
lever cable shield.
Install the selector lever cable shield.
4WD vehicles
6. Install the front driveshaft in the vehicle.
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft
Speed Sensor - 5R55S > Page 1353
7. Connect the front driveshaft to the transfer case.
^ Tighten to 30 Nm (22 lb-ft).
8. Connect the front driveshaft to the front differential.
^ Tighten to 19 Nm (14 lb-ft).
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Speed Sensor - 5R55S > Page 1354
Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor - 5R55S
Turbine Shaft Speed (TSS) Sensor
Turbine Shaft Speed (TSS) Sensor
Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
Four wheel drive (4WD) vehicles
2. Disconnect the front driveshaft from the transfer case.
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft
Speed Sensor - 5R55S > Page 1355
3. Disconnect the front driveshaft from the front differential.
4. Remove the front driveshaft from the vehicle.
All vehicles
5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield
closest to the boot, then sliding the selector lever
cable shield away from the boot.
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft
Speed Sensor - 5R55S > Page 1356
6. Remove the selector lever cable and selector lever cable 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.
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Speed Sensor - 5R55S > Page 1357
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.
2 Tighten the TSS sensor screw.
^ Tighten to 14 Nm (10 lb-ft).
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 selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable
bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable
to make sure that it is locked into the selector lever cable 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 selector lever cable end is correctly installed.
Install the selector lever cable and selector lever bracket. ^
Tighten to 40 Nm (30 lb-ft).
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Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft
Speed Sensor - 5R55S > Page 1358
4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new shield.
Install the selector lever cable shield.
4WD vehicles
5. Install the front driveshaft in the vehicle.
6. Connect the front driveshaft to the transfer case.
^ Tighten to 30 Nm (22 lb-ft).
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Speed Sensor - 5R55S > Page 1359
7. Connect the front driveshaft to the front differential.
^ Tighten to 19 Nm (14 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
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Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 1364
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
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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 1365
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1366
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
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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 1367
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1368
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1369
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1370
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1371
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1372
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1373
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1374
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1375
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 1376
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element
Switch > Component Information > Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element
Switch > Component Information > Locations > Page 1381
C2347
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Rear Window Adjust Switch
View 151-37
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Rear Window Adjust Switch > Page 1386
Power Window Switch: Locations Window Adjust Switch
View 151-34
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Rear Window Adjust Switch > Page 1387
View 151-33
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Rear Window Adjust Switch > Page 1388
View 151-32
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Component Information > Locations > Rear Window Adjust Switch > Page 1389
View 151-31
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Rear Window Adjust Switch
C980
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Rear Window Adjust Switch > Page 1392
Power Window Switch: Diagrams Master Window Adjust Switch
C504A
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Rear Window Adjust Switch > Page 1393
C504B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Rear Window Adjust Switch > Page 1394
Power Window Switch: Diagrams Window Adjust Switch
C604
C701
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Rear Window Adjust Switch > Page 1395
C801
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch
Power Window Switch: Testing and Inspection Master Window Adjust Switch
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1398
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1399
Power Window Switch: Testing and Inspection Window Adjust Switches - Passenger Side and
Rear Doors
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1400
Power Window Switch: Testing and Inspection Rear Window Adjust Switch
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Page 1401
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 (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid
Level Switch > Component Information > Locations
Washer Fluid Level Switch: Locations
View 151-2
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid
Level Switch > Component Information > Locations > Page 1406
View 151-5
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Level Switch > Component Information > Locations > Page 1407
C138
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations
Windshield Washer Switch: Locations
View 151-14
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Page 1411
View 151-15
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Page 1412
C202
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Testing and Inspection > Multifunction Switch
Windshield Washer Switch: Testing and Inspection Multifunction Switch
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 1415
Windshield Washer Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 1416
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Testing and Inspection > Page 1417
Windshield Washer Switch: Service and Repair
Steering Column Multifunction Switch
NOTE: Steering wheel removed for clarity.
Steering Column Multifunction Switch (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Testing and Inspection > Page 1418
Steering Column Multifunction Switch (Part 2)
Removal and Installation
CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or
damage to the column may result.
1. Disconnect the battery ground cable. 2. Remove the 2 screws and the steering column opening
cover. 3. Remove the 3 screws and the upper and lower steering column shrouds. 4. Disconnect
the multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the
multi-function switch.
^ To install, tighten to 3 Nm (27 lb-inch).
6. To install, reverse the removal procedure.
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Component Information > Locations
Wiper Switch: Locations
View 151-14
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Locations > Page 1422
View 151-15
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Locations > Page 1423
C202
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Testing and Inspection > Multifunction Switch
Wiper Switch: Testing and Inspection Multifunction Switch
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Testing and Inspection > Multifunction Switch > Page 1426
Wiper Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Testing and Inspection > Multifunction Switch > Page 1427
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Testing and Inspection > Page 1428
Wiper Switch: Service and Repair
Steering Column Multifunction Switch
NOTE: Steering wheel removed for clarity.
Steering Column Multifunction Switch (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Testing and Inspection > Page 1429
Steering Column Multifunction Switch (Part 2)
Removal and Installation
CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or
damage to the column may result.
1. Disconnect the battery ground cable. 2. Remove the 2 screws and the steering column opening
cover. 3. Remove the 3 screws and the upper and lower steering column shrouds. 4. Disconnect
the multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the
multi-function switch.
^ To install, tighten to 3 Nm (27 lb-inch).
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications
Alignment: Specifications Alignment Specifications
Alignment Specifications
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications >
Page 1435
Alignment: Specifications General Specifications
General Specifications
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications >
Page 1436
Alignment: Specifications Torque Specifications
Torque Specifications
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1437
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 flagnut with a non-flagnut 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 (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1438
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.
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.
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 (V8-4.6L (2008))
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
following 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 lb-ft).
4. NOTE: 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 arm rearward nut.
6. Position the LF lower 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment - Front > Page 1441
Tighten the LF lower arm rearward nut to 200 Nm (148 lb-ft).
8. Recheck the camber and caster, adjust as necessary. 9. Check and, if necessary, adjust the
front toe.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment - Front > Page 1442
Alignment: Service and Repair Ride Height Measurement
Ride Height Measurement
Front Ride Height Measurement
Front Ride Height Measurement
NOTE: Make sure that the vehicle is positioned on a flat, level surface and the tires are inflated to
the correct pressure. Vehicle should have a full tank of fuel.
1. Position a suitable surface gauge (such as Starrett 57D Surface Gauge), on a flat, level surface
and adjust the gauge's arm until the scriber point is
located in the center of the lower arm inboard bolt. ^
Lock the surface gauge in this position.
2. With the surface gauge positioned on a flat, level surface, record the measurement of the
surface gauge position (measurement A).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment - Front > Page 1443
3. Position the surface gauge on the same flat, level surface as used in Step 1, adjust the gauge's
arm until the scriber point is located in the center of
the shock absorber lower bolt. ^
Lock the surface gauge in this position.
4. With the surface gauge positioned on a flat, level surface, record the measurement of the
surface gauge position (measurement B).
5. Subtract measurement B from measurement A to obtain the front ride height.
^ Refer to Specifications.
Rear Ride Height Measurement
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment - Front > Page 1444
Rear Ride Height Measurement
NOTE: Make sure that the vehicle is positioned on a flat, level surface and the tires are inflated to
the correct pressure. Vehicle should have a full tank of fuel.
1. Measure the distance between the flat level surface and the center of the lower arm inboard bolt
(measurement A). 2. Measure the distance between the flat level surface and the center of the
shock absorber lower bolt (measurement B). 3. Subtract measurement B from measurement A to
obtain the rear ride height.
^ Refer to Specifications.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment - Front > Page 1445
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.
6. Rotate the front wheel inner tie rods until the toe setting is within specification.
7. 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 lb-ft).
8. Install the clamps. 9. Recheck the toe settings and adjust if necessary.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment - Front > Page 1446
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 lb-ft).
7. Recheck the toe settings and adjust if necessary.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment - Front > Page 1447
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 flagnut must be removed and replaced with a non-flagnut 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.
3. Using alignment equipment and the manufacturer's instructions, measure the rear camber.
4. 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.
5. NOTE: Make sure that the camber settings are not disturbed while tightening the nut.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment - Front > Page 1448
Tighten the upper arm inboard nut to 250 Nm (185 lb-ft).
6. Recheck the camber settings and adjust as necessary. 7. Check and, if necessary, adjust the
rear toe.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (KOEO)..............................................................................................................
.............................................207-276 kPa (30-40 psi) Engine running.................................................
..................................................................................................................................207-276 kPa
(30-40 psi)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information
> Specifications > Page 1453
Fuel Pressure: Testing and Inspection
FUEL SYSTEM PRESSURE TEST
Special Tool(s)
Special Tool(s)
WARNING:
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious personal injury.
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the
fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under
high pressure, even when the engine is not running. Failure to follow this instruction may result in
serious 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 component. Highly flammable mixtures are always
present and may be ignited. Failure to follow these instructions may result in serious personal
injury.
- When handling fuel, always observe fuel handling precautions and be prepared in the event of
fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources.
Failure to follow these instructions may result in serious personal injury.
1. Disconnect the fuel supply tube-to-fuel rail spring lock coupling.
2. NOTE: 4.6L shown, 4.0L similar.
Install the special tool in line between the fuel supply tube and fuel rail.
3. NOTE: The inertia fuel shutoff (IFS) switch electrical connector was disconnected during fuel
system pressure release.
Connect the IFS switch electrical connector.
4. 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.
5. Test the fuel system pressure to make sure it is within the specified range.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information
> Specifications > Page 1454
6. NOTE:
- 4.6L shown, 4.0L similar.
- Open the drain valve slowly to relieve the fuel system pressure. This may drain fuel from the
system. Place the fuel in a suitable container.
Upon completion of the fuel system pressure test, open the drain valve on the special tool and
relieve the fuel system pressure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Specifications
Idle Speed: Specifications
Typical Diagnostic Reference Value
Measured/PID Values 630 - 850 RPM ................................................................................................
...................................................................................................... Hot Idle
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Coolant Expansion Tank
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair > Page 1462
Intake Air System Components (4.0L SOHC)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair > Page 1463
Intake Air System Components - 4.6L (3V)
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 (ACL) outlet pipe.
Vehicles equipped with a 4.6L (3V) engine
2. Detach the wiring harness retainer from the coolant expansion tank.
All vehicles
3. Loosen the clamp and disconnect the ACL outlet pipe from the ACL. 4. Unclip and remove the
ACL cover. 5. Remove the ACL.
6. NOTE: Clean the inside of the ACL tray.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious personal injury.
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the
fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under
high pressure, even when the engine is not running. Failure to follow this instruction may result in
serious 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 (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component
Information > Specifications
Firing Order: Specifications
Firing order...........................................................................................................................................
...........................................................1-3-7-2-6-5-4-8
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 before top dead center (BTDC)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Service and Repair
Ignition Cable: Service and Repair
Ignition Components RH Side
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Service and Repair > Page 1477
Ignition Components LH Side
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions
Spark Plug: Technical Service Bulletins Ignition System - Spark Plug Removal Instructions
TSB 08-7-6
04/14/08
SPARK PLUG REMOVAL INSTRUCTIONS - 4.6L 3V/5.4L 3V16.8L 3V
FORD: 2005-2008 Mustang 2004-2008 F-150 2005-2008 Expedition, F-Super Duty 2006-2008
Explorer, F-53 Motorhome Chassis 2007-2008 Explorer Sport Trac
LINCOLN: 2005-2008 Navigator 2006-2008 Mark LT
MERCURY: 2006-2008 Mountaineer
This article supersedes TSB 08-1-9 to update Vehicle Applications, Service Procedure and Part
List.
ISSUE Some 2004-2008 F-150, 2006-2008 Mark LT, 2005-2008 F-Super Duty, Expedition, and
Navigator, with 5.4L 3-V engine; 2005-2008 Mustang, 2006-2008 Explorer, Mountaineer, and
2007-2008 Explorer Sport Trac with 4.6L 3-V engine; 2005-2008 F-Super Duty, 2006-2008 and
F-Stripped Chassis, with 6.8L 3-V engine may experience difficulty with spark plug removal. This
may cause damage to the spark plug and leave part of the spark plug in the cylinder head. Affected
engine build dates are as follows: 5.4L 3-V and 6.8L 3-V before 10/9/07, 4.6L 3-V before 11/30/07.
ACTION Refer to the following Service Procedure for techniques to remove the spark plugs and
extract broken spark plugs.
SERVICE PROCEDURE
The engine build date can be read on the left hand cam cover information sticker.
To remove spark plugs without damage, it is necessary to adhere exactly to this procedure before
removal is attempted.
CAUTION
DO NOT REMOVE PLUGS WHEN THE ENGINE IS WARM OR HOT. THE ENGINE MUST BE AT
ROOM TEMPERATURE WHEN PERFORMING SPARK PLUG SERVICE. REMOVING THE
SPARK PLUGS FROM A WARM/HOT ENGINE INCREASES THE CHANCE THE THREADS
COULD BE DAMAGED.
Spark Plug Removal Procedure
1. Remove the coil-on-plug assemblies and thoroughly blow out the spark plug wells and
surrounding valve cover area with compressed air.
2. Back out the spark plugs no more than 1/8 to 1/4 of a turn. Using Motorcraft(R) Carburetor
Tune-Up Cleaner, fill the spark plug well just above where the jamb nut hex sits (1/2 - 3/4
teaspoon). A minimum period of 15 minutes of soak time is required. The cleaner will wick down to
the ground electrode shield and soften the carbon deposits in this time. DO NOT WORK the spark
plug back and forth at this point.
NOTE
COMPLETELY REVIEW THE PRODUCT LABEL FOR THE MOTORCRAFT CARBURETOR
TUNE-UP CLEANER PRODUCT - USE AT ROOM TEMPERATURE AND SHAKE WELL.
CAUTION
EXCESSIVE MOTORCRAFT(R) CARBURETOR TUNE-UP CLEANER, OR REPEATING THE
PROCESS SEVERAL TIMES WITH TOO MUCH CLEANER FLUID, COULD INTRODUCE
ENOUGH LIQUID VOLUME TO HYDRO-LOCK THE ENGINE.
CAUTION
DO NOT USE AIR OR POWER TOOLS FOR SPARK PLUG REMOVAL. SPARK PLUGS MUST
ONLY BE REMOVED WITH HAND TOOLS.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1482
3. Tighten, and then loosen the spark plug, working the plug back and forth. Some screeching and
high effort may be noticed. The expected removal torque is about 33 lb-ft (45 N.m). Repeat the
back and forth turning as needed until turning effort is reduced, and remove the spark plugs.
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP. (Figure 1)
Separated/Broken Spark Plug Removal
If the spark plug separates after following the Spark Plug Removal Procedure, it will fail in one of
three modes. Refer to the appropriate removal procedure as required.
a. Mode 1: The ground electrode shield is left behind as an empty shell. (Figure 2)
b. Mode 2: The entire porcelain insulator and ground electrode shield remains in the cylinder head.
(Figure 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1483
c. Mode 3: The upper section of porcelain broke off with remaining porcelain left inside the ground
shield. (Figure 4)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1484
Flowchart of procedure. (Figure 5)
Mode 1 Procedure:
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1485
Use Rotunda special service tool 303-1203 to remove an empty ground electrode shield from the
cylinder head. (Figure 6)
NOTE
THIS TOOL IS ONLY DESIGNED TO WORK WITH AN EMPTY GROUND ELECTRODE SHIELD.
IF PORCELAIN REMAINS, PROCEED TO MODE 2 OR 3 REMOVAL.
1. Modify vacuum cap to a 3/8" (10 mm) length for each ground electrode shield that needs to be
removed. (Figure 7)
2. Use the installation rod (J) provided with service tool 303-1203 update to install the modified
vacuum cap. Push the cap into the ground shield down to the electrode strap. This will plug and
protect the combustion chamber from contamination. (Figure 7)
3. Thread-tap the ground electrode shield using a 9.0 x 1.0 mm plug tap (tap profile is about 3-4
reduced diameter threads on the tip end).
a. Coat the end of the tap with general purpose grease. (Figure 8)
b. Turn the tap about 3 to 4 turns into the ground electrode shield. Back the tap up frequently to
break chips and avoid cut material from coiling-up in the spark plug well. A tap socket adaptor (K)
is provided with service tool 303-1203 update to connect the tap to a 3/8" socket
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1486
drive.
CAUTION
DO NOT ATTEMPT TO REMOVE THE GROUND ELECTRODE SHIELD WITH THE TAP AND
WRENCH. THE TAP MAY BREAK IF THIS IS ATTEMPTED.
4. Thread Rotunda special service tool 303-1203 into the ground electrode shield. (Figure 9)
a. Install the stepped end of the tool pilot bushing into the spark plug well ensuring it bottoms out.
b. Screw the center shank into the ground electrode shield. Do not over tighten the shank, to
prevent thread stripping.
c. Install the nylon washer and jack nut until finger tight.
d. Turn the jack nut until the ground electrode is freed from the cavity and withdraw the tool
assembly.
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP.
Mode 2 Procedure:
1. Add an additional 1/2 teaspoon Motorcraft® Carburetor Tune-Up Cleaner fluid into spark plug
well and allow 15 minutes of soak time.
2. Using long-reach nose pliers grasp and remove the porcelain with an up and down motion taking
care not to fracture the porcelain.
3. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder
head.
Mode 3 Procedure:
CAUTION
DO NOT DRIVE PORCELAIN DOWN INTO THE GROUND SHIELD WITH A PUNCH AS
FRAGMENTS MAY ENTER THE COMBUSTION CHAMBER.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1487
Use Rotunda special service tool kit 303-1398 to remove porcelain broken inside the ground
electrode shield. (FIGURE 10)
Porcelain Removal - Preparation
CAUTION
THE ENGINE AND THE BONDING ADHESIVE MUST BE ROOM TEMPERATURE OF 70 °F (21
°C) OR HIGHER FOR PROPER CURE AND BOND STRENGTH. VERIFY EXPIRATION DATE OF
ADHESIVE.
CAUTION
DO NOT REUSE PINS. THIS ENSURES THE CORRECT SURFACE CHARACTERISTICS FOR
BONDING.
1. Remove any remaining electrode material from broken porcelain with long nose reach pliers.
2. Spray Motorcraft® Metal Brake Parts Cleaner into the porcelain hole for 2-4 seconds using the
straw nozzle supplied with the brake cleaner can.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1488
3. Insert a pin (A) into the collet (B). Screw the collet onto the threaded rod (C). Install the
assembled collet, pin, and threaded rod into the steel tool pilot (F). (Figures 11 and 12)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1489
4. Retract the collet and pin into the steel tool pilot, protecting the pin. (Figures 13 and 14)
NOTE
PIN TIP DAMAGE OR BENT PINS WILL PREVENT INSERTION INTO THE PORCELAIN.
5. Insert the completed assembly into the spark plug well and fully engage the pin into the
porcelain. (Figure 15)
6. Spray Motorcraft(R) Metal Brake Parts Cleaner 2-4 seconds between the spark plug well and
steel tool pilot. The steel tool pilot must be lifted up approximately 1/2" to allow brake cleaner to
flood the porcelain and pin.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1490
7. Scrub the porcelain inside diameter by moving the threaded rod up and down vigorously. Take
care making sure the pin does not disengage the porcelain. (Figure 16).
8. Repeat Steps 6 and 7.
9. Remove the tool assembly. Again flood the porcelain with Motorcraft(R) Metal Brake Parts
Cleaner for 2-4 seconds, then blow out the entire spark plug well and porcelain with dry
compressed air.
NOTE
CLEAN AND DRY COMPONENTS ARE KEY TO BONDING THE PIN TO THE PORCELAIN.
10. Repeat Steps 1-9 to prepare remaining porcelain fragments as needed.
11. Disassemble the collet and pin from the threaded rod. Dry the tools thoroughly with dry
compressed air.
Porcelain Removal - Bonding Process
CAUTION
USE CARE TO PREVENT BONDING AGENT FROM CONTACTING THREADS IN CYLINDER
HEAD.
NOTE
WORKING TIME LIMIT OF LOCTITE(R) 638(TM) RETAINING COMPOUND IS 5 MINUTES.
1. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to opposite sides of a clean and dry
applicator (H). Excessive amounts of Loctite(R) 638(TM) are being used if it drips off the applicator.
(Figure 17)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1491
2. Insert applicator into the porcelain and move applicator up and down 1/2" (13 mm) while turning
to spread the Loctite® 638TM on the inside of the porcelain. (Figure 18).
3. Add additional Loctite(R) 638(TM), repeating Steps 1 and 2.
4. Clean the applicator with Motorcraft(R) Metal Brake Parts Cleaner before the bonding agent
starts to cure.
5. Reassemble a dry and clean collet and pin assembly.
6. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to the pin. Excessive amounts of
Loctite® 638TMare being used if it drips off the pin.
7. Retract the collet and pin into the steel tool pilot to protect the Loctite(R) 638(TM) coated pin.
8. Insert the completed assembly into spark plug well and fully engage the pin into the porcelain
with a twisting motion to spread the bonding agent.
9. Add additional Loctite® 638TM, repeating Steps 6-8.
10. Leave the pin fully inserted in the porcelain while the adhesive cures. Replace the steel tool
pilot with the aluminum alignment sleeve (G), Figure 9, to support the threaded rod while the
adhesive cures if additional porcelain fragments are present in other cylinders. (Figure 19).
CAUTION
A MINIMUM 1 HOUR CURING TIME AT 70 °F (21 °C) DEGREES IS REQUIRED BEFORE
EXTRACTION IS ATTEMPTED.
11. Allow the Loctite(R) 638(TM) to cure for a minimum of one hour at 70 °F (21 °C).
12. Repeat the bonding process for remaining cylinders as needed.
Porcelain Removal - Extraction
1. After a minimum of one hour curing at 70 °F (21 °C), install the steel pilot tool over the threaded
rod.
2. Install the washer and jack nut until finger tight against the tool pilot bushing.
CAUTION
ONLY THE STEEL PILOT TOOL IS ACCEPTABLE FOR USE IN PORCELAIN REMOVAL.
3. While holding the end of the threaded rod with a wrench, tighten the jack nut until the porcelain is
free of the ground electrode.
4. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder
head.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1492
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP. (FIGURE 7)
Porcelain Removal - Pin Slipped Out
In the unlikely event that the pin does not remove the broken porcelain, this process can be
repeated.
Key elements to success are:
^ Clean and dry porcelain
^ Sufficient Loctite® 638TM Retaining Compound spread uniformly
^ Loctite(R) 638(TM) cure time and temperature
^ Preventing the threaded rod from rotating while removing the porcelain
Replacement Supplies
Replacement kit components and additional kit consumables (Loctite(R) 638TM Retaining
Compound and pins) can be obtained by calling 1-800-ROTUNDA, Option 5.
Parts Block
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
MT080706 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
12405 01
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (not adjustable)............................................................................................................
...................................1.02-1.28 mm (0.040-0.050 in)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > General Specifications > Page 1495
Torque Specifications
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 1496
Spark Plug: Application and ID
Item.......................................................................................................................................................
..............................................................Specification
Spark plug type (early build - black coil boot).......................................................................................
....................................................................PZT-14F Spark plug type (late build - brown coil boot)....
....................................................................................................................................................HJFS
-24FP
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 1497
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.
^
Install new spark plugs.
4. Inspect for normal burning.
^ Check for light tan or gray deposits on the firing tip.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 1498
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(R) 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 a 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.
^ Install new spark plugs.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 1499
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 1500
Spark Plug: Service and Repair
Ignition Components RH Side
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 1501
Ignition Components LH Side
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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.
Compression Pressure Limit Chart (Part 1)
Compression Pressure Limit Chart (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications > Page 1505
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 (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications > Page 1506
Compression Pressure Limit Chart (Part 2)
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
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 (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System
Information > Specifications
Valve Clearance: Specifications
Valve Clearance
This engine is equipped with hydraulic lash adjusters. No adjustment is required.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer
Interest for Drive Belt: > 09-9-7 > May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start
Drive Belt: Customer Interest Engine - FEAD Idler Pulley Noise During Cold Start
TSB 09-9-7
05/18/09
COLD START FEAD HOOT - WHISTLE NOISE
FORD: 2007-2008 Mustang, Expedition, Explorer Sport Trac, Explorer, F-150, F-150
LINCOLN: 2007-2008 Mark LT, Navigator
MERCURY: 2007-2008 Mountaineer
This article supersedes TSB 8-4-2 to remove the production build date.
ISSUE Some 2007-2008 F-150, Mustang vehicles equipped with a 4.6L and 5.4L engine;
2007-2008 Mark LT, Expedition, Navigator vehicles equipped with a 5.4L engine; Explorer,
Mountaineer, Explorer Sport Trac vehicles with 4.6L engine may exhibit a front end accessory drive
(FEAD) related high-pitched metallic whistle/hoot noise after a cold soak in ambient temperatures
below 40 °F (4.4 °C). This noise may be caused by the grooved nylon FEAD idler pulley.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
FEAD IDLER PULLEY NOISE MAY BE MOST APPARENT AT OR NEAR COLD ENGINE IDLE
SPEEDS (APPROXIMATELY 1200 RPM). NOISE DURATION IS LESS THAN 10 MINUTES
AFTER STARTUP AND WILL BE ELIMINATED WITH FEAD BELT REMOVED.
1. Replace the nylon FEAD idler pulley, refer to Workshop Manual, 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
090907A 2007-2008 F-150/Mark LT 0.3 Hr.
4.6L/5.4L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do
Not Use With 8678A, 8620F)
090907A 2007-2008 0.4 Hr.
Expedition/Navigator: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine
Belt (Do Not Use With 8678A, 8620F)
090907A 2007-2008 0.4 Hr.
Explorer/Mountaineer/
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer
Interest for Drive Belt: > 09-9-7 > May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start > Page 1518
Sport Trac 4.6L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt
(Do Not Use With 8678A, 8620F)
090907A 2007-2008 Mustang 4.6L: 0.3 Hr.
Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With
8678A, 8620F)
DEALER CODING
CONDITION
BASIC PART NO. CODE
6C348 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Drive Belt: > 09-9-7 > May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start
Drive Belt: All Technical Service Bulletins Engine - FEAD Idler Pulley Noise During Cold Start
TSB 09-9-7
05/18/09
COLD START FEAD HOOT - WHISTLE NOISE
FORD: 2007-2008 Mustang, Expedition, Explorer Sport Trac, Explorer, F-150, F-150
LINCOLN: 2007-2008 Mark LT, Navigator
MERCURY: 2007-2008 Mountaineer
This article supersedes TSB 8-4-2 to remove the production build date.
ISSUE Some 2007-2008 F-150, Mustang vehicles equipped with a 4.6L and 5.4L engine;
2007-2008 Mark LT, Expedition, Navigator vehicles equipped with a 5.4L engine; Explorer,
Mountaineer, Explorer Sport Trac vehicles with 4.6L engine may exhibit a front end accessory drive
(FEAD) related high-pitched metallic whistle/hoot noise after a cold soak in ambient temperatures
below 40 °F (4.4 °C). This noise may be caused by the grooved nylon FEAD idler pulley.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
FEAD IDLER PULLEY NOISE MAY BE MOST APPARENT AT OR NEAR COLD ENGINE IDLE
SPEEDS (APPROXIMATELY 1200 RPM). NOISE DURATION IS LESS THAN 10 MINUTES
AFTER STARTUP AND WILL BE ELIMINATED WITH FEAD BELT REMOVED.
1. Replace the nylon FEAD idler pulley, refer to Workshop Manual, 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
090907A 2007-2008 F-150/Mark LT 0.3 Hr.
4.6L/5.4L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do
Not Use With 8678A, 8620F)
090907A 2007-2008 0.4 Hr.
Expedition/Navigator: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine
Belt (Do Not Use With 8678A, 8620F)
090907A 2007-2008 0.4 Hr.
Explorer/Mountaineer/
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Drive Belt: > 09-9-7 > May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start > Page 1524
Sport Trac 4.6L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt
(Do Not Use With 8678A, 8620F)
090907A 2007-2008 Mustang 4.6L: 0.3 Hr.
Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With
8678A, 8620F)
DEALER CODING
CONDITION
BASIC PART NO. CODE
6C348 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1525
Drive Belt: Diagrams
Component Locations - 4.6L (3V)
Component Locations - 4.6L (3V) (Part 1)
Component Locations - 4.6L (3V) (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection
and Diagnostic Overview
Drive Belt: Initial Inspection and Diagnostic Overview
Inspection and Verification
CAUTION: 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. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
mechanical damage.
Visual Inspection Chart
Visual Inspection Chart
Belt Tensioner With Belt Length Indicator
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection
and Diagnostic Overview > Page 1528
3. Check that the belt length indicator, if equipped, on the belt tensioner is in the acceptable belt
installation and wear range. If the indicator is in the
belt replacement range, either an incorrect belt is installed or the belt is worn beyond the service
limit. Install a new belt as necessary.
4. Eliminate all other non-belt related noises that could cause belt misdiagnosis, such as A/C
compressor engagement chirp, A/C slugging noise,
power steering cavitations at low temperatures, variable camshaft timing (VCT) tick or generator
whine.
5. If a concern is found, correct the condition before proceeding to the next step.
V-Ribbed Serpentine Drive Belt With Cracks Across Ribs
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection
and Diagnostic Overview > Page 1529
6. Check the belt for cracks. Up to 15 cracks in a rib over a distance of 100 mm (4.0 in) can be
considered acceptable. If cracks exceed this standard,
install a new belt.
V-Ribbed Serpentine Belt With Piling
7. 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 Chunks of Rib Missing
8. There should be no chunks missing from the belt ribs. If the belt shows any evidence of this,
install a new accessory drive belt. 9. 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 (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection
and Diagnostic Overview > Page 1530
Drive Belt: Symptom Related Diagnostic Procedures
Symptom Chart
Symptom Chart (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection
and Diagnostic Overview > Page 1531
Symptom Chart (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection
and Diagnostic Overview > Page 1532
Drive Belt: Component Tests and General Diagnostics
Component Tests
Drive Belt - Noise/Flutter
CAUTION: 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.
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.
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 (WOT) 1-2 and 2-3 shifts or 2-3 and 3-4 back out shifts on automatic
transmissions.
^ WOT 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 or idler pulley(s) 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
CAUTION: Incorrect accessory drive belt installation will cause excessive drive belt wear and may
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection
and Diagnostic Overview > Page 1533
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 and wear, especially the mounting
pad surface and arm alignment. If the accessory drive belt tensioner is not installed correctly, the
mounting surface pad will be out of position. If the tensioner arm is worn, the arm will be out of
alignment. Either of these conditions 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
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.
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 from the tensioner. Carry out the following tests: ^
Using the 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.
^ Rotate the tensioner pulley by hand and check for a binding, contaminated or seized condition.
^ Inspect the area surrounding the accessory drive belt tensioner for oil leaks or contamination and
repair any leaks.
3. If the accessory drive belt tensioner does not meet the criteria in the previous step, install a new
tensioner. If the accessory drive belt tensioner
meets the criteria in the previous step, proceed to testing the tensioner dynamically.
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
A/C clutch cycles (if equipped), or when the engine is accelerated rapidly. If the accessory drive
belt tensioner movement is excessive without A/C clutch cycling or engine acceleration, check belt
rideout. Excessive belt rideout (uneven depth of grooves in the belt) can cause excessive
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection
and Diagnostic Overview > Page 1534
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 (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 1535
Drive Belt: Service and Repair
Accessory Drive Belt - 4.6L (3V)
Front End Accessory Drive (FEAD) - Exploded View, 4.6L (3V)
Removal and Installation
1. Remove the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air
Induction. 2. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive
belt.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 1536
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Coolant Expansion Tank
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information >
Service and Repair > Page 1542
Intake Air System Components (4.0L SOHC)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information >
Service and Repair > Page 1543
Intake Air System Components - 4.6L (3V)
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 (ACL) outlet pipe.
Vehicles equipped with a 4.6L (3V) engine
2. Detach the wiring harness retainer from the coolant expansion tank.
All vehicles
3. Loosen the clamp and disconnect the ACL outlet pipe from the ACL. 4. Unclip and remove the
ACL cover. 5. Remove the ACL.
6. NOTE: Clean the inside of the ACL tray.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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:
- When working on or near the evaporative emission (EVAP) system, disconnect the battery ground
cable from the battery. The EVAP system contains fuel vapor and condensed fuel vapor, so an
electrical spark may cause a fire or explosion. Failure to follow this instruction may result in serious
personal injury.
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious 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 (EVAP) system. See: Powertrain Management/Emission
Control Systems/Evaporative Emissions
System/Testing and Inspection
8. Carry out the evaporative emission repair drive cycle.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
5R55S - Automatic Transaxle/Transmission
Fluid Filter - A/T: Service and Repair 5R55S - Automatic Transaxle/Transmission
Fluid Pan, Gasket and Filter
Fluid Pan, Gasket and Filter
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Place a drain pan under the transmission
fluid pan.
3. Remove the transmission fluid drain plug and drain the transmission fluid.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
5R55S - Automatic Transaxle/Transmission > Page 1554
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid gasket should be
reused.
Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid gasket.
5. Remove and discard the transmission fluid pan filter.
6. Clean and inspect the transmission fluid pan and magnet.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
5R55S - Automatic Transaxle/Transmission > Page 1555
Installation
1. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with
clean transmission fluid.
NOTE: Make sure that the transmission fluid filter seals are correctly seated on the transmission
fluid filter.
Lubricate the transmission fluid filter seals and install the transmission fluid pan filter. ^
Tighten to 10 Nm (89 lb-inch).
2. Install the transmission 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 transmission fluid pan gasket should be
reused.
Install the transmission fluid pan gasket on the transmission fluid pan.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
5R55S - Automatic Transaxle/Transmission > Page 1556
4. Install the transmission fluid pan and transmission fluid pan gasket and loosely install the
transmission fluid pan screws.
5. Tighten the transmission fluid pan screws in a crisscross sequence.
^ Tighten to 11 Nm (8 lb-ft).
6. Install the transmission fluid drain plug.
^ Tighten to 26 Nm (19 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
5R55S - Automatic Transaxle/Transmission > Page 1557
7. Partially fill the transmission.
Transmission Filter - In Line
Transmission Filter - In Line
NOTE: Use the following guidelines for installing the transmission fluid in-line filter:
^ If the transmission was overhauled and the vehicle was equipped with an in-line transmission
fluid filter, install a new in-line transmission fluid filter.
^ If the transmission was overhauled and the vehicle was not equipped with an in-line transmission
fluid filter, install a new in-line transmission fluid filter kit.
^ If the transmission is being installed for a non-internal repair, do not install an in-line transmission
fluid filter or in-line transmission fluid filter kit.
^ If installing a Ford-authorized remanufactured transmission, install a new in-line transmission fluid
filter.
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the secondary latch from the
transmission fluid cooler connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
5R55S - Automatic Transaxle/Transmission > Page 1558
3. Using the special tool, disconnect the transmission fluid cooler connector.
4. Remove the section of the transmission fluid cooler tube at the second flare.
^ Clean and deburr the cut end of the transmission fluid cooler tube.
5. NOTE: Be sure the transmission fluid 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 transmission 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 transmission fluid cooler hose as illustrated.
7. CAUTION: The transmission fluid cooler filter has a bypass valve in it. The red arrow on the
transmission fluid filter indicates the
direction of transmission fluid flow through the filter. The transmission fluid filter must be installed in
the transmission fluid cooler return line with the red arrow on the transmission fluid filter pointing
away from the transmission fluid cooler and toward the transmission (the transmission fluid return
line has transmission fluid coming out of the transmission fluid cooler going to the transmission). If
the transmission fluid filter is not installed correctly, it will cause internal transmission damage.
CAUTION: Do not install any transmission fluid cooler hoses or transmission fluid cooler tubes with
a bend entering the transmission fluid filter greater than 60 degrees. Doing so can block
transmission fluid flow and cause internal transmission damage.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
5R55S - Automatic Transaxle/Transmission > Page 1559
Install the one end of the transmission fluid filter into the transmission fluid cooler hose with a
clamp. ^
Tighten the transmission fluid cooler hose clamp.
8. Using a suitable length of hose, install the other end of the transmission fluid filter into the tubing
ferrule hose assembly with 2 clamps.
^ Tighten the hose clamps.
9. Clean a section of the transmission fluid pan, then install the sticker.
10. Fill the transmission with clean transmission fluid.
^ Verify for correct operation.
^ Check the filter for leaks.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
5R55S - Automatic Transaxle/Transmission > Page 1560
Fluid Filter - A/T: Service and Repair 6R60 - Automatic Transaxle/Transmission
Fluid Pan, Gasket and Filter
Removal
CAUTION: The use of any other transmission fluid than specified, can result in the transmission
failing to operate in a normal manner or transmission failure.
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid fill plug
transmission fluid level indicator assembly located on the passenger side front portion of the
transmission
case. Removal of the transmission fluid fill plug will relieve any vacuum that might have built up in
the transmission. This will allow the transmission fluid pan to be easily removed when the bolts are
removed.
3. Remove the transmission fluid pan and allow the transmission fluid to drain.
4. Remove the transmission fluid pan gasket.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
5R55S - Automatic Transaxle/Transmission > Page 1561
5. Remove and discard the transmission fluid filter.
6. Clean and inspect the transmission fluid pan and magnet.
Installation
NOTE: If the transmission is being repaired for a contamination-related failure, install a new
transmission fluid filter and seal assembly. The transmission fluid filter may be reused if no
excessive contamination is indicated.
1. Inspect the transmission case for the transmission fluid filter seal. If the transmission fluid filter
seal is in the case, carefully remove the
transmission fluid filter seal without scratching the case.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
5R55S - Automatic Transaxle/Transmission > Page 1562
2. Make sure that the transmission fluid filter seal is on the transmission fluid filter and lubricate the
transmission fluid filter seal with clean
transmission fluid.
3. Install a new transmission fluid filter.
4. Position the magnet in the transmission fluid pan.
5. NOTE: The transmission fluid pan gasket can be reused if not damaged.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
5R55S - Automatic Transaxle/Transmission > Page 1563
Install a new transmission fluid pan gasket if required.
6. Install the transmission fluid pan and tighten the bolts in a crisscross pattern.
^ Tighten to 14 Nm (10 lb-ft).
7. Using the transmission fluid refill procedure, fill the transmission with clean transmission fluid.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious personal injury.
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the
fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under
high pressure, even when the engine is not running. Failure to follow this instruction may result in
serious 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 (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair
Coolant Line/Hose: Service and Repair
Coolant Crossover Manifold Assembly
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair >
Page 1572
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair >
Page 1573
Removal and Installation
1. Drain the engine cooling system. 2. Remove the intake manifold. 3. Rotate the accessory drive
belt tensioner clockwise and detach the belt from the generator pulley.
4. Disconnect the electrical connector. 5. Loosen the generator nuts.
^ To install, tighten to 25 Nm (18 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair >
Page 1574
6. 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 lb-in).
7. Disconnect the PCV heater hose from the coolant crossover manifold assembly. 8. Disconnect
the heater hose from the coolant crossover manifold assembly. 9. Disconnect the upper radiator
hose from the coolant crossover manifold assembly.
10. Remove the bolts, the coolant crossover manifold assembly and the gaskets. Discard the
gaskets.
^ To install, tighten to 10 Nm (89 lb-in).
11. To install, reverse the removal procedure.
^ Install new gaskets.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary
Heater Outlet and Inlet Line - Front > Page 1579
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary
Heater Outlet and Inlet Line - Front > Page 1580
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.
- 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 (V8-4.6L (2008))
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. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the air
cleaner (ACL) and ACL outlet tube. 4. Remove the compressor-to-condenser discharge line
bracket nut and detach the bracket.
- To install, tighten to 9 Nm (80 lb-in).
5. Remove the compressor outlet fitting nut and disconnect the fitting.
- Discard the O-ring seal and gasket seal.
- To install, tighten to 15 Nm (11 lb-ft).
6. Remove the 2 coolant expansion tank bolts and position the coolant expansion tank aside.
- To install, tighten to 7 Nm (62 lb-in).
7. Disconnect the A/C pressure transducer electrical connector. 8. Remove the condenser inlet
fitting nut and disconnect the fitting.
- Discard the O-ring seal.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor to Condenser Discharge Line > Page 1585
- To install, tighten to 8 Nm (71 lb-in).
9. NOTE: The LH clip should be disconnected from the line. The RH clip should be disconnected
from the cooling module.
Detach the 2 compressor-to-condenser discharge line clips at the cooling module.
10. Remove the compressor-to-condenser discharge line. 11. 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.
12. Evacuate, leak test and charge the refrigerant system.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor to Condenser Discharge Line > Page 1586
Hose/Line HVAC: Service and Repair Condenser To Evaporator Line
CONDENSER TO EVAPORATOR LINE
Removal and Installation
All vehicles
1. Remove the air cleaner (ACL) and ACL outlet tube. 2. Recover the refrigerant. 3. Remove the
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.
7. Remove the condenser-to-evaporator line bracket nut.
- To install, tighten to 7 Nm (62 lb-in).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor to Condenser Discharge Line > Page 1587
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 (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor to Condenser Discharge Line > Page 1588
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 (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor to Condenser Discharge Line > Page 1589
Part 2
Removal and Installation
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 (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor to Condenser Discharge Line > Page 1590
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 (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor to Condenser Discharge Line > Page 1591
Part 2
Removal and Installation
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 (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor to Condenser Discharge Line > Page 1592
Hose/Line HVAC: Service and Repair
Compressor to Condenser Discharge Line
COMPRESSOR TO CONDENSER DISCHARGE LINE
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the air
cleaner (ACL) and ACL outlet tube. 4. Remove the compressor-to-condenser discharge line
bracket nut and detach the bracket.
- To install, tighten to 9 Nm (80 lb-in).
5. Remove the compressor outlet fitting nut and disconnect the fitting.
- Discard the O-ring seal and gasket seal.
- To install, tighten to 15 Nm (11 lb-ft).
6. Remove the 2 coolant expansion tank bolts and position the coolant expansion tank aside.
- To install, tighten to 7 Nm (62 lb-in).
7. Disconnect the A/C pressure transducer electrical connector. 8. Remove the condenser inlet
fitting nut and disconnect the fitting.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor to Condenser Discharge Line > Page 1593
- Discard the O-ring seal.
- To install, tighten to 8 Nm (71 lb-in).
9. NOTE: The LH clip should be disconnected from the line. The RH clip should be disconnected
from the cooling module.
Detach the 2 compressor-to-condenser discharge line clips at the cooling module.
10. Remove the compressor-to-condenser discharge line. 11. 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.
12. Evacuate, leak test and charge the refrigerant system.
Condenser To Evaporator Line
CONDENSER TO EVAPORATOR LINE
Removal and Installation
All vehicles
1. Remove the air cleaner (ACL) and ACL outlet tube. 2. Recover the refrigerant. 3. Remove the
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor to Condenser Discharge Line > Page 1594
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.
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.
Auxiliary Evaporator Outlet and Inlet Line - Front
AUXILIARY EVAPORATOR OUTLET AND INLET LINE - FRONT
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor to Condenser Discharge Line > Page 1595
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor to Condenser Discharge Line > Page 1596
Part 2
Removal and Installation
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.
Auxiliary Evaporator Outlet and Inlet Line - Rear
AUXILIARY EVAPORATOR OUTLET AND INLET LINE - REAR
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor to Condenser Discharge Line > Page 1597
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor to Condenser Discharge Line > Page 1598
Part 2
Removal and Installation
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.
Suction Accumulator To Compressor Line
SUCTION ACCUMULATOR TO COMPRESSOR LINE
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor to Condenser Discharge Line > Page 1599
Removal and Installation
1. Recover the refrigerant. 2. Remove the suction accumulator outlet fitting nut.
- To install, tighten to 8 Nm (71 lb-in).
3. Disconnect the auxiliary evaporator outlet line fitting.
- Discard the O-ring seals.
4. Remove the suction accumulator-to-compressor line bracket nut.
- To install, tighten to 7 Nm (62 lb-in).
5. Remove the suction accumulator-to-compressor line middle fitting nut and disconnect the fitting.
- Discard the O-ring seal.
- To install, tighten to 8 Nm (71 lb-in).
6. Remove the rear suction accumulator-to-compressor line.
- Discard the O-ring seal.
7. NOTE: The compressor suction fitting nut can be accessed through the RH wheel well.
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).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor to Condenser Discharge Line > Page 1600
8. Remove the front suction accumulator-to-compressor line. 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.
Suction Accumulator To Evaporator Line
SUCTION ACCUMULATOR TO EVAPORATOR LINE
Removal and Installation
All vehicles
1. Remove the suction accumulator. 2. 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).
3. Remove the ground strap bolt at the dash panel.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor to Condenser Discharge Line > Page 1601
4. Disconnect the evaporator outlet fitting.
- Discard the O-ring seals.
Vehicles with 4.0L engine
5. Disconnect he evaporative emissions return line fitting at the intake manifold.
6. Remove the fuel line bracket bolt at the rear of the RH valve cover.
7. Remove the wire harness bolt at the rear of the RH cylinder head.
All vehicles
8. Remove the suction accumulator-to-evaporator line. 9. To install, reverse the removal procedure.
- Install new O-ring seals.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor to Condenser Discharge Line > Page 1602
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Page 1606
Removal
CAUTION: While repairing the power steering system, care should be taken to prevent the entry of
foreign material or failure of the power steering components may result.
1. With the vehicle in NEUTRAL, position it on a hoist. 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 power steering fluid cooler from the steering gear.
^ Discard the O-ring seal.
5. Disconnect the pressure line from the steering gear.
^ Discard the O-ring seal.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Page 1607
6. Remove the pressure line bracket-to-engine nut (4.6L) or bolt (4.0L). 7. Remove the pressure
line bracket-to-crossmember bolt. 8. Disconnect the pressure line-to-pump fitting.
^ Remove and discard the Teflon(R) seal.
9. Remove the pressure line.
Installation
1. NOTE: new Teflon(R) seal must be installed.
Using the special tool, install a new Teflon(R) seal on the pressure line fitting.
2. Position the pressure line and connect the pressure line-to-pump fitting.
^ Tighten to 65 Nm (48 lb-ft).
3. Install the pressure line bracket-to-engine nut (4.6L) or bolt (4.0L).
^ Tighten to 11 Nm (8 lb-ft).
4. NOTE: New O-rings must be installed whenever the pressure line and fluid cooler are
disconnected from the steering gear.
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 lb-ft).
6. Install a new O-ring seal and position the power steering fluid cooler 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 lb-ft).
8. Install the power steering pump pulley. 9. Fill the power steering system.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity
Specifications
Coolant: Capacity Specifications
Coolant Capacity:
Without auxiliary climate control
............................................................................................................................................................
13.9 qts (13.2L)
With auxiliary climate control ...............................................................................................................
.................................................. 15.7 qts (14.9L)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity
Specifications > Page 1616
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 (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Specifications
Fluid - A/T: Capacity Specifications
Transmission Fluid 5R55 .....................................................................................................................
............................................................................... 12.4 Quarts ( 11.7 L ) 6R60 .................................
..............................................................................................................................................................
..... 12.2 Quarts ( 11.6 L )
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 (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Specifications > Page 1621
Fluid - A/T: Fluid Type Specifications
Transmission Fluid Type
5R55S ..................................................................................................................................................
............................................................. MERCON V 6R60 ..................................................................
..............................................................................................................................................
MERCON SP
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission
Fluid - A/T: Service and Repair 5R55S - Automatic Transaxle/Transmission
Transmission Fluid Level Check
Transmission Fluid Level Check
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1624
Transmission 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 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. 7. Hold the larger transmission fluid drain plug with
a wrench and remove the small (center) transmission fluid level indicating plug.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1625
8. Install the special tool into the pan.
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 transmission fluid.
10. Hang the special tool under the vehicle. Position it upright and close to the transmission.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1626
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. Transmission fluid will immediately
start flowing out of the special tool into the transmission fluid pan.
13. Add 0.5L (1 pt) of transmission fluid into the transmission fluid pan. Stop the process by
releasing the air pressure and removing the air nozzle
from the end of the hose.
14. Inspect the transmission fluid level in the special tool. If the transmission fluid drains back into
the canister, the transmission is full. If no
transmission fluid drains back, more transmission 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 transmission fluid trapped in the system and direct it into the
container.
16. Allow the transmission fluid to drain. Make sure that the fluid temperature is between 27-49° C
(80-120° F). When the transmission fluid comes
out as a thin stream or drip, the transmission fluid is at the correct level.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1627
17. Reinstall the small (center) transmission fluid level indicating plug using a 3/16-inch Allen key.
^ Tighten to 10 Nm (89 lb-inch).
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.
Transmission Fluid Drain and Refill - Automated Equipment
Transmission Fluid Drain and Refill - Automated Equipment
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 or transmission
damage can occur.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1628
1. With the vehicle in PARK, position it on a hoist. 2. Use a suitable flush and fill machine to change
the fluid. 3. When connecting the flush and fill machine, connect the machine to the transmission
fluid cooler tube after the transmission fluid cooler on the
transmission fluid cooler return tube. This will help remove any foreign material trapped in the
transmission fluid coolers.
Refill
1. Use only clean transmission fluid. 2. Once the transmission 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
transmission fluid is needed, add transmission
fluid in increments of 0.24L (0.5 pt) until the correct level is achieved. For additional information,
refer to Transmission Fluid Level Check. See: Transmission and Drivetrain/Automatic
Transmission/Transaxle/Service and Repair/Procedures/Transmission Fluid Level Check
Transmission Fluid Drain and Refill -Without Torque Converter Drain Plug
Transmission Fluid Drain and Refill -Without Torque Converter Drain Plug
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1629
Fluid Fill Reference
NOTE: Left side of case shown.
Fluid Fill Reference
Draining
1. With the vehicle in PARK, position it on a hoist. Set the vehicle as close to level as possible. 2.
Remove the transmission fluid drain plug (large plug) and allow the fluid to drain.
Refill
1. Install the transmission fluid drain plug.
^ Tighten to 26 Nm (19 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1630
2. Hold the larger transmission fluid drain plug with a wrench and remove the small (center)
transmission fluid level indicating plug.
3. Install the special tool into the transmission fluid 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 transmission fluid.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1631
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.
7. Apply a maximum of 206.85 kPa (30 psi) to the open end of the vacuum/pressure hose from the
special tool. Transmission fluid will immediately
start flowing out of the special tool into the transmission fluid pan.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1632
8. Add 1.89L or 2.83L (2 qt or 3 qt) of transmission fluid into the transmission 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 transmission fluid level in the special tool. If the fluid drains back into the canister,
the transmission is full. If no transmission fluid
drains back, more transmission 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 transmission fluid to drain. When the transmission fluid comes out as a thin stream or
drip, the transmission fluid is at the correct level.
13. Reinstall the small (center) transmission fluid level indicating plug.
^ Tighten to 10 Nm (89 lb-inch).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1633
Transmission Fluid Cooler Backflushing and Cleaning
Transmission Fluid Cooler Backflushing and Cleaning
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. Failure to follow these instructions
may result in transmission failure.
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. ^
Connect the cleaner tank pressure line to the steel transmission cooler return tube (longest tube).
^ Connect a tank return hose to the steel transmission cooler pressure tube (shorter tube). 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 tube.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1634
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 tube.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1635
Fluid - A/T: Service and Repair 6R60 - Automatic Transaxle/Transmission
Transmission Fluid Level Check
Transmission Fluid Level Check
CAUTION: The vehicle should not be driven if the transmission fluid level is low as internal failure
could result.
CAUTION: The transmission fluid fill plug is located near the exhaust system. The exhaust will be
extremely hot during this procedure.
NOTE: If the vehicle has been operated for an extended period at high highway speeds, in city
traffic, during hot weather or while pulling a trailer, the transmission fluid must cool down to obtain
an accurate reading.
NOTE: If the transmission starts to slip, shifts slowly or shows signs of transmission fluid leaking,
the transmission fluid level should be checked.
NOTE: Do not overfill the transmission. The transmission fluid level must be at the upper level of
the crosshatch mark.
NOTE: If the installation of a new transmission fluid cooler, cooler tubes have been carried out the
vehicle must be driven to get the transmission fluid to a temperature of 88° C (190° F) in order to
purge the air from the transmission fluid cooling system.
1. With the engine running, place the transmission selector lever in each gear position and hold
approximately 5 seconds. Place the transmission
selector lever in PARK.
2. With the engine idling (600-750 rpm) in PARK, position it on a hoist. 3. Remove the transmission
fluid fill plug transmission fluid level indicator assembly, located on the passenger side front portion
of the transmission
case.
4. Separate the transmission fluid level indicator from the transmission fluid fill plug.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1636
5. Wipe the transmission fluid level indicator clean. Reinstall the transmission fluid level indicator
only back into the transmission fluid fill plug hole
to check the transmission fluid level.
6. Using the scan tool, verify that the transmission fluid temperature is between 80° C-85° C (175°
F-185° F). Do not overfill the transmission. The
transmission fluid level must be at the upper level of the crosshatch mark.
7. NOTE: If the transmission fluid is not at the correct level, follow the steps for Adding Additional
Transmission Fluid or Removing Transmission
Fluid.
Install the transmission fluid fill plug. ^
Tighten to 35 Nm (26 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1637
Transmission Fluid Drain and Refill
Transmission Fluid Drain and Refill
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1638
Drain
1. With the vehicle in NEUTRAL, position it on a hoist.
2. NOTE: Some transmission fluid leakage may occur when removing the transmission fluid fill
plug.
Remove the transmission fluid fill plug transmission fluid level indicator assembly located on the
passenger side front portion of the transmission case. Removal of the transmission fluid fill plug will
relieve any vacuum that might have built up in the transmission. This will aid in allowing the
transmission fluid pan to be easily removed when the bolts are removed.
3. Remove the transmission fluid pan and allow the transmission fluid to drain.
4. NOTE: The transmission fluid pan gasket can be reused if not damaged.
Install a new transmission fluid pan gasket, if required.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1639
5. Install the transmission fluid pan.
^ Tighten to 14 Nm (10 lb-ft).
Transmission Fluid Refill
CAUTION: This procedure contains the air purge steps required to purge air from the transmission
fluid cooling system. This procedure is NOT intended for use with the Transmission Fluid Level
Check.
CAUTION: The vehicle should not be driven if the transmission fluid level is low as internal failure
could result.
CAUTION: The transmission fluid fill plug is located near the exhaust system. The exhaust will be
extremely hot during this procedure.
CAUTION: The use of any other transmission fluid than specified, can result in the transmission
failing to operate in a normal manner or transmission failure.
NOTE: If the transmission starts to slip, shifts slowly or shows signs of transmission fluid leaking,
the transmission fluid level should be checked.
NOTE: Here is an overview of the Transmission Fluid Drain and Refill procedure.
^ Adding 3.3L (3.5 qt) of clean transmission fluid to the transmission is an initial fill enabling you to
start the engine.
^ The cold transmission fluid level range shown in the procedure allows the vehicle to be driven.
^ The vehicle should be driven to allow the transmission fluid temperature to reach 85° C-88° C
(185° F-190° F) in order to purge the air from the transmission fluid cooling system.
^ Fill the transmission fluid to the full range on the transmission fluid level indicator at the normal
operating range 80° C-85° C (175° F-185° F).
1. NOTE: The transmission will need 3.3L (3.5 qt) of clean transmission fluid added to the
transmission as an initial fill if:
^ the transmission has been overhauled.
^ a new mechatronic assembly has been installed.
^ the transmission fluid pan or transmission fluid filter have been removed.
Using the special tool, add 3.3L (3.5 qt) of clean transmission fluid to the transmission through the
transmission fluid fill hole.
2. Check the transmission fluid level cold.
1 The vehicle is safe to drive if the transmission fluid is in the cold level range 32° C-43° C (90°
F-110° F).
^ With the engine running, use the scan tool to monitor transmission fluid temperature and engine
speed. Place the transmission selector lever in each gear position and hold approximately 5
seconds. Place the transmission selector lever in PARK, with the engine at idle (600-750 rpm).
3. Separate the transmission fluid level indicator from the transmission fluid fill plug.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1640
4. Wipe the transmission fluid level indicator clean. Reinstall the transmission fluid level indicator
only back into the transmission fluid fill plug hole
to check the transmission fluid level. Repeat this until a consistent reading is established.
5. Add clean transmission fluid to the cold level location as shown in the illustration.
1 Transmission fluid cold level.
6. Install the transmission fluid fill plug.
^ Tighten to 35 Nm (26 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1641
7. While driving the vehicle, use the scan tool to verify that the transmission fluid temperature has
reached a temperature of 88° C (190° F). This will
circulate the transmission fluid through the torque converter and the transmission fluid cooling
system, eliminating any trapped air in the cooling system. ^
With the engine idling (600-750 rpm) in PARK, verify that the transmission fluid temperature is
between 80° C-85° C (175° F-185° F).
8. Remove the transmission fluid fill plug transmission fluid level indicator assembly located on the
passenger side front portion of the transmission
case.
9. Separate the transmission fluid level indicator from the transmission fluid fill plug.
10. Wipe the transmission fluid level indicator clean. Reinstall the transmission fluid level indicator
only back into the transmission fluid fill plug hole
to check the transmission fluid level. Repeat this until a consistent reading is established.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1642
11. Using the scan tool verify that the transmission fluid temperature is between 80° C-85° C (175°
F-185° F). The transmission fluid level must be at
the upper level of the crosshatch mark.
12. NOTE: If the transmission fluid is not at the correct level, follow the steps for Adding Additional
Transmission Fluid or Removing Transmission
Fluid in this procedure.
Install the transmission fluid fill plug. ^
Tighten to 35 Nm (26 lb-ft).
Adding Additional Transmission Fluid
NOTE: To get an accurate transmission fluid level reading the engine should be idling (600-750
rpm) in PARK.
1. Install the special tool into the transmission fluid fill hole.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1643
2. Fill the special tool with approximately 0.47L (1 pt) of clean transmission fluid.
3. Hang the special tool under the vehicle, upright and close to the transmission.
4. Connect the special tools.
^ Connect the open end of the hose from the special tool onto the special tool from the
transmission case.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1644
5. Apply a maximum of 206.85 kPa (30 psi) to the open end of the vacuum/pressure hose from the
special tool. Transmission fluid will immediately
start flowing out of the special tool into the transmission.
6. NOTE: Do not overfill the transmission. The transmission fluid level must be at the upper level of
the crosshatch mark.
Reinstall the transmission fluid level indicator only back into the transmission fluid fill plug hole to
check the transmission fluid level. Repeat this until a consistent reading is established.
7. Using the scan tool verify that the transmission fluid temperature is between 80° C-85° C (175°
F-185° F). The transmission fluid level must be at
the upper level of the crosshatch mark.
8. NOTE: If the transmission fluid is over full, follow the steps for Removing Transmission Fluid in
this procedure.
Install the transmission fluid fill plug. ^
Tighten to 35 Nm (26 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1645
Removing Transmission Fluid
NOTE: To get an accurate transmission fluid level reading the engine should be idling (600-750
rpm) in PARK.
1. If the transmission is overfilled, transmission fluid must be removed to the correct level. Use the
special tools to extract any excessive transmission
fluid.
2. Using the scan tool, verify that the transmission fluid temperature is between 80° C-85° C (175°
F-185° F). The transmission fluid level must be at
the upper level of the crosshatch mark. Reinstall the transmission fluid level indicator only back into
the transmission fluid fill plug hole to check the transmission fluid level. Repeat this until a
consistent reading is established.
3. Install the transmission fluid fill plug.
^ Tighten to 35 Nm (26 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Automatic Transaxle/Transmission > Page 1646
Transmission Fluid Cooler Backflushing and Cleaning
Transmission Fluid Cooler Backflushing and Cleaning
CAUTION: When internal damage occurs in the transmission, metal particles and clutch plate
material can travel into the torque converter and the transmission fluid cooler. These contaminates
are a major cause of recurring transmission concerns. To prevent further concerns, remove these
contaminates from the transmission fluid cooler tubes and install a new transmission fluid cooler
before placing the transmission in use.
CAUTION: Do not attempt to install an in-line transmission fluid filter on this vehicle, damage to the
transmission fluid cooling system or transmission could occur.
1. Install a new transmission fluid cooler if any transmission fluid leaks are indicated or a major
metallic failure is indicated. 2. Using a suitable torque converter/fluid cooler cleaner, flush the
transmission fluid cooler and tubes.
3. NOTE: Rubber hoses must be attached to the ends of the transmission fluid cooler tubes, to aid
in connecting them to the cleaner.
Connect the cleaner pressure and return lines appropriately in the following sequence. 1
Connect the pressure line to the transmission fluid cooler inlet tube.
2 Connect the return line to the transmission fluid cooler outlet tube.
3 Place the outlet end of the return line in the transmission fluid tank reservoir.
4. NOTE: Cycling the fluid pump ON and OFF will help dislodge contaminants in the cooler system.
Switch the fluid pump ON. Allow the transmission fluid to circulate a minimum of 5 minutes.
5. Switch the fluid pump OFF. 6. Disconnect the cleaner pressure line at the transmission fluid
cooler tube. 7. Using compressed air, blow through the transmission fluid cooler inlet tube until all
transmission fluid is removed. 8. Remove the rubber hoses from the transmission fluid cooler
tubes.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity
Specifications > Page 1651
Fluid - Differential: Fluid Type Specifications
Differential Fluid Type
Type ................................................................................................................................ SAE
75W-140 High Performance Synthetic Rear Axle Lubricant
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Page
1652
Fluid - Differential: Service and Repair
Differential Draining and Filling
Fluid Drain and Fill
1. Remove both the fill plug and the drain plug.
^ Drain the axle assembly.
2. Clean and install the drain plug.
^ Tighten to 34 Nm (25 lb-ft).
3. Fill the axle with 1.65L (3.5 pt) of axle lubricant to the bottom of the fill plug hole. 4. Clean and
install the fill plug.
^ Tighten to 34 Nm (25 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Specifications
Engine Oil: Capacity Specifications
Engine Oil Capacity .............................................................................................................................
............................................................... 5.7L (6.0 qt)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Specifications > Page 1657
Engine Oil: Fluid Type Specifications
Engine Oil
U.S. .........................................................................................................................................
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil Canada
....................................................................................................................................................
Motorcraft SAE 5W-20 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-M2C930-A.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications
Power Steering Fluid: Specifications
Power Steering Fluid Type
Ford Part Name ...................................................................................................................................
................................ Motorcraft MERCON V ATF Ford Part Number .................................................
............................................................................................................................................. XT-5-QM
Ford Specification ................................................................................................................................
......................................................... MERCON V
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Page
1661
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.
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 an extended amount of time. Damage
to the power steering pump may 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 1.89L (2 qt) of power
steering fluid.
10. CAUTION: Do not hold the steering wheel at the stops for an extended amount of time.
Damage to the power steering pump may 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. Using the special tool (UV lamp), inspect the system for traces of UV dye. Repair as necessary.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications
Refrigerant: Capacity Specifications
R-134a Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada)..........WSH-M17B19-A
(Specification) - 0.88 kg (31 oz) (vehicles without auxiliary
systems) (Fill Capacity)
R-134a Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada)...............WSH-M17B19-A
(Specification) - 1.33 kg (47 oz) (vehicles with auxiliary
systems) (Fill Capacity)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications > Page 1666
Refrigerant: Fluid Type Specifications
R-134a Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada)..........WSH-M17B19-A
(Specification) - 0.88 kg (31 oz) (vehicles without auxiliary
systems) (Fill Capacity)
R-134a Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada)...............WSH-M17B19-A
(Specification) - 1.33 kg (47 oz) (vehicles with auxiliary
systems) (Fill Capacity)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity
Specifications
Refrigerant Oil: Capacity Specifications
Climate Control System
PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D....................WSH-M1C231-B
(Specification) - 266 ml (9 fl oz) (vehicles without auxiliary
systems) (Fill Capacity)
PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D.......................WSH-M1C231-B
(Specification) - 473 ml (16 fl oz) (vehicles with auxiliary
systems) (Fill Capacity)
Auxiliary Climate Control
PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D.............WSH-M1C231-B
(Specification) - 47 ml (16 fl oz) (with auxiliary climate control)
(Fill Capacity)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity
Specifications > Page 1671
Refrigerant Oil: Fluid Type Specifications
Climate Control System
PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D....................WSH-M1C231-B
(Specification) - 266 ml (9 fl oz) (vehicles without auxiliary
systems) (Fill Capacity)
PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D.......................WSH-M1C231-B
(Specification) - 473 ml (16 fl oz) (vehicles with auxiliary
systems) (Fill Capacity)
Auxiliary Climate Control
PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D.............WSH-M1C231-B
(Specification) - 47 ml (16 fl oz) (with auxiliary climate control)
(Fill Capacity)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 1680
13480A, 9818A8)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2455 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 1686
13480A, 9818A8)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2455 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 1692
13480A, 9818A8)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2455 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Hydraulic
Control Unit (HCU) Bleeding
Brake Bleeding: Service and Repair ABS Hydraulic Control Unit (HCU) Bleeding
ABS Hydraulic Control Unit (HCU) Bleeding
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification.
Additionally, do not use brake fluid that has been previously drained. Following these instructions
will help prevent system contamination, brake component damage and the risk of serious 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 serious personal injury.
WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master
cylinder may be damaged if operated without fluid, resulting in degraded braking performance.
Failure to follow this instruction may result in serious 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.
NOTE: This procedure is only required when a new hydraulic control unit (HCU) is installed.
NOTE: When any part of the hydraulic system is disconnected for repair or installation of new
components, air can get into the system and cause spongy brake pedal action. This requires
bleeding of the hydraulic system after it is correctly connected. The hydraulic system can be bled
manually or with pressure bleeding equipment.
1. NOTE: Carrying out the System Bleed function drives trapped air from the HCU. Subsequent
bleeding removes the air from the brake hydraulic
system through the bleeder screws.
NOTE: Adequate voltage to the HCU module is required during the anti-lock control portion of the
system bleed.
Connect the scan tool to the vehicle.
2. Access the ABS HCU bleed function and follow the directions on the scan tool. 3. Manually
bleed the brake hydraulic system. 4. Repeat the procedure carrying out a total of 2 scan tool cycles
and 2 manual bleed cycles.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Hydraulic
Control Unit (HCU) Bleeding > Page 1695
Brake Bleeding: Service and Repair Component Bleeding
Component Bleeding
Master Cylinder
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification.
Additionally, do not use brake fluid that has been previously drained. Following these instructions
will help prevent system contamination, brake component damage and the risk of serious 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 serious personal injury.
WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master
cylinder may be damaged if operated without fluid, resulting in degraded braking performance.
Failure to follow this instruction may result in serious personal injury.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If spilled, wipe up immediately
before damage to the painted or plastic surface occurs.
NOTE: When any part of the hydraulic system has been disconnected for repair or installation of
new components, air can enter the system and cause spongy brake pedal action. This requires
bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can
be bled manually or with pressure bleeding equipment.
NOTE: When 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 entering the system.
1. Disconnect the brake tubes from the master cylinder.
2. Install 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 (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Hydraulic
Control Unit (HCU) Bleeding > Page 1696
3. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes, without air
bubbles. 4. Remove the short brake tubes and install the brake outlet tubes. 5. Bleed each brake
tube at the brake master cylinder as follows:
1 Have an assistant pump the brake pedal at least 2 times and then hold firm pressure on the
brake pedal.
2 Loosen the rearmost brake tube fitting until a stream of brake fluid comes out. While the assistant
maintains pressure on the brake pedal, tighten 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.
5 Tighten the master cylinder brake tube fittings to 18 Nm (13 lb-ft).
6. Bleed the brake system.
Brake Caliper
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification.
Additionally, do not use brake fluid that has been previously drained. Following these instructions
will help prevent system contamination, brake component damage and the risk of serious 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 serious personal injury.
WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master
cylinder may be damaged if operated without fluid, resulting in degraded braking performance.
Failure to follow this instruction may result in serious personal injury.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If spilled, wipe up immediately
before damage to the painted or plastic surface occurs.
NOTE: It is not necessary to do a complete brake system bleed if only the brake caliper was
disconnected or installed new.
1. Remove the brake caliper bleeder screw cap and place a box-end wrench on the bleeder screw.
Attach a rubber drain hose to the bleeder screw and
submerge the free end of the hose 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.
Loosen the bleeder screw until a stream of brake fluid comes out. While the assistant maintains
pressure on the brake pedal, tighten the bleeder
screw. ^
Repeat until clear, bubble-free fluid comes out.
^ Refill the brake master cylinder reservoir as necessary.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Hydraulic
Control Unit (HCU) Bleeding > Page 1697
4. Tighten the brake caliper bleeder screw, remove the rubber hose and install the bleeder screw
cap.
^ Tighten the front brake caliper bleeder screw to 10 Nm (89 lb-in).
^ Tighten the rear brake caliper bleeder screw to 22 Nm (16 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Hydraulic
Control Unit (HCU) Bleeding > Page 1698
Brake Bleeding: Service and Repair Brake System Bleeding
Brake System Bleeding
Pressure Bleed
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification.
Additionally, do not use brake fluid that has been previously drained. Following these instructions
will help prevent system contamination, brake component damage and the risk of serious 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 serious personal injury.
WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master
cylinder may be damaged if operated without fluid, resulting in degraded braking performance.
Failure to follow this instruction may result in serious 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.
NOTE: When any part of the hydraulic system has been disconnected for repair or installation of
new components, air can get into the system and cause spongy brake pedal action. This requires
bleeding of the hydraulic system after it has been correctly connected.
NOTE: Pressure bleed the brake system at 207-345 kPa (30-50 psi).
1. NOTE: If the hydraulic control unit (HCU) or any component upstream of the HCU are installed
new, carry out the Brake System Pressure
Bleeding procedure, then the anti-lock HCU bleed procedure, followed by another Brake System
Bleed Procedure.
Clean all the dirt from around the brake fluid reservoir cap and remove the cap. Fill the brake
master cylinder reservoir with clean, specified brake fluid.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Hydraulic
Control Unit (HCU) Bleeding > Page 1699
2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers
of pressure bleeding equipment. Follow the
instructions of the manufacturer when installing the adapter.
Install the bleeder adapter to the brake master cylinder reservoir and attach the bleeder tank hose
to the fitting on the adapter.
3. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake
fluid to complete the bleeding operation.
Remove the RH rear brake caliper bleeder cap and place a box-end wrench on the bleeder screw.
Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a
container partially filled with clean, specified brake fluid.
4. Open the valve on the bleeder tank. 5. Loosen the RH rear brake caliper bleeder screw. Leave
open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw.
^ Press and release the parking brake 5 times.
^ Repeat until clear, bubble-free fluid comes out.
6. Tighten the RH rear brake caliper bleeder screw to 22 Nm (16 lb-ft), remove the rubber hose and
install the bleeder screw cap. 7. Repeat Steps 5 and 6 for the LH rear brake caliper.
^ Tighten the LH rear brake caliper bleeder screw to 22 Nm (16 lb-ft).
8. Continue bleeding the front of the system, going in order from the RH front brake caliper and
then to the LH front brake caliper.
^ Tighten the front brake caliper bleeder screws to 10 Nm (89 lb-in).
9. Close the bleeder tank valve. Remove the tank hose from the adapter and remove the adapter.
Fill the reservoir with clean, specified brake fluid
and install the reservoir cap.
Manual Bleeding
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification.
Additionally, do not use brake fluid that has been previously drained. Following these instructions
will help prevent system contamination, brake component damage and the risk of serious 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 serious personal injury.
WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master
cylinder may be damaged if operated without fluid, resulting in degraded braking performance.
Failure to follow this instruction may result in serious 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.
NOTE: When any part of the hydraulic system is disconnected for repair or installation of new
components, air can get into the system and cause spongy brake pedal action. This requires
bleeding of the hydraulic system after it is correctly connected. The hydraulic system can be bled
manually or with pressure bleeding equipment.
1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master
cylinder reservoir with clean, specified brake fluid.
2. NOTE: Bleed the brake system from the longest to the shortest brake line.
Remove the RH rear brake caliper bleeder screw cap and place a box-end wrench on the bleeder
screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a
container partially filled with clean, specified brake fluid.
3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 4.
Loosen the RH rear brake caliper bleeder screw until a stream of brake fluid comes out. While the
assistant maintains pressure on the brake pedal,
tighten the bleeder screw.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Hydraulic
Control Unit (HCU) Bleeding > Page 1700
^ Repeat until clear, bubble-free fluid comes out.
^ Refill the brake master cylinder reservoir as necessary.
5. Tighten the RH rear brake caliper bleeder screw to 22 Nm (16 lb-ft), remove the rubber hose and
install the bleeder screw cap. 6. Repeat Steps 2 through 5 for the LH rear brake caliper bleeder
screw.
^ Tighten the LH rear brake caliper bleeder screw to 22 Nm (16 lb-ft).
7. Remove the RH front brake caliper bleeder screw cap and place a box-end wrench on the
bleeder screw. Attach a rubber drain hose to the bleeder
screw and submerge the free end of the hose in a container partially filled with clean, specified
brake fluid.
8. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 9.
Loosen the RH front brake caliper bleeder screw until a stream of brake fluid comes out. While the
assistant maintains pressure on the brake pedal,
tighten the bleeder screw. ^
Repeat until clear, bubble-free fluid comes out.
^ Refill the brake master cylinder reservoir as necessary.
10. Tighten the RH front brake caliper bleeder screw to 10 Nm (89 lb-in), remove the rubber hose
and install the bleeder screw cap. 11. Repeat Steps 7 through 10 for the LH front brake caliper
bleeder screw.
^ Tighten the LH front brake caliper bleeder screw to 10 Nm (89 lb-in).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 eye protection when servicing a vehicle. Failure to follow this instruction may result in
serious personal injury.
- Never probe the electrical connectors on air bag, safety canopy or side air curtain modules.
Failure to follow this instruction may result in the accidental deployment of these modules, which
increases the risk of serious personal injury or death.
- 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 this
instruction may result in the accidental deployment of the safety canopy and cause serious
personal injury or death.
- To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to
follow this instruction may result in serious personal injury or death.
NOTE: The air bag warning indicator 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.
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 warning indicator for at least 30 seconds.
The air bag warning indicator will remain lit
continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning
indicator does not remain lit continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition switch to OFF.
6. WARNING: Always deplete the backup power supply before repairing or installing any new front
or side air bag supplemental restraint
system (SRS) component and before servicing, removing, installing, adjusting or striking
components near the front or side impact sensors or the restraints control module (RCM). Nearby
components include doors, instrument panel, console, door latches, strikers, seats and hood
latches.
Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and
impact sensor(s).
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Failure to follow these instructions may result in serious personal injury or death in the event of an
accidental deployment.
Disconnect the battery ground cable and wait at least one minute.
Repowering Procedure
1. Turn the ignition switch from OFF to ON. 2. Install RCM fuse 17 (10A) to the SJB and close the
cover.
3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of
any air bag module when the battery is
connected. Failure to follow these instructions may result in serious personal injury in the event of
an accidental deployment. Connect the
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Supplemental Restraint System (SRS) Depowering and Repowering > Page 1705
battery ground cable.
Connect the battery ground cable.
4. 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 warning indicator with the air bag modules installed. The air bag
warning indicator will light continuously for approximately 6 seconds and then turn off. If an SRS
fault is present, the air bag warning indicator will: fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag warning 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 warning 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 warning
indicator and any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the RCM and occupant classification system module (OCSM)
using a scan tool.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Supplemental Restraint System (SRS) Depowering and Repowering > Page 1706
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 eye protection when servicing a vehicle. Failure to follow this instruction may result in
serious personal injury.
- Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear
seam pointed away from the body. Do not set a live air bag module down with the deployment
door/trim cover/tear seam face down. Failure to follow these instructions may result in serious
personal injury in the event of an accidental deployment.
- Never probe the electrical connectors on air bag, safety canopy or side air curtain modules.
Failure to follow this instruction may result in the accidental deployment of these modules, which
increases the risk of serious personal injury or death.
- Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive
load limiting retractors. Failure to follow this instruction may result in the accidental deployment of
the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious
personal injury or death.
- 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.
- To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to
follow this instruction may result in serious personal injury or death.
NOTE: The air bag warning indicator 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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Supplemental Restraint System (SRS) Depowering and Repowering > Page 1707
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 warning indicator for at least 30 seconds.
The air bag warning indicator will remain lit
continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning
indicator does not remain lit continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: Always deplete the backup power supply before repairing or installing any new front
or side air bag supplemental restraint
system (SRS) component and before servicing, removing, installing, adjusting or striking
components near the front or side impact sensors or the restraints control module (RCM). Nearby
components include doors, instrument panel, console, door latches, strikers, seats and hood
latches.
Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and
impact sensor(s).
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Failure to follow these instructions may result in serious personal injury or death in the event of an
accidental deployment.
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.
9. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Supplemental Restraint System (SRS) Depowering and Repowering > Page 1708
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.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Supplemental Restraint System (SRS) Depowering and Repowering > Page 1709
15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat
side air bag module electrical connector.
Explorer and Mountaineer vehicles 16. Release and position aside the passenger side C-pillar trim
panel.
17. Disconnect the passenger side safety canopy module electrical connector.
18. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy module electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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19. Release and position aside the driver side C-pillar trim panel.
20. Disconnect the driver side safety canopy module electrical connector.
21. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy module electrical connector.
Explorer Sport Trac vehicles 22. Remove the driver and passenger side upper C-pillar trim panels.
23. Disconnect the passenger side safety canopy module electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Supplemental Restraint System (SRS) Depowering and Repowering > Page 1711
24. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy module electrical connector.
25. Disconnect the driver side safety canopy module electrical connector.
26. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy module electrical connector.
All vehicles 27. 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Supplemental Restraint System (SRS) Depowering and Repowering > Page 1712
28. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air
bag module electrical connector.
29. Install the RCM fuse 17 (10A) to the SJB. 30. 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. 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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Supplemental Restraint System (SRS) Depowering and Repowering > Page 1713
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.
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 10. Remove the restraint system diagnostic tool from the
vehicle harness side of the driver side safety canopy module electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Supplemental Restraint System (SRS) Depowering and Repowering > Page 1714
11. Connect the driver side safety canopy module electrical connector.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Supplemental Restraint System (SRS) Depowering and Repowering > Page 1715
15. Install the passenger side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
All vehicles 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Supplemental Restraint System (SRS) Depowering and Repowering > Page 1716
19. Connect the LH side passenger air bag module electrical connector.
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 driver air bag module electrical connectors are unique and cannot be reversed
when connected to 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. Damage to the connector or component
may occur.
Connect the driver air bag module electrical connectors as noted in removal.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Supplemental Restraint System (SRS) Depowering and Repowering > Page 1717
24. Install the 2 driver air bag module bolts (1 shown).
- Tighten to 7 Nm (62 lb-in).
25. 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.
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: Make sure no one is in the vehicle and there is nothing blocking or placed in front
of any air bag module when the battery is
connected. Failure to follow these instructions may result in serious personal injury in the event of
an accidental deployment.
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 warning indicator with the air bag modules installed. The air bag
warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag
SRS fault is present, the air bag warning indicator will: fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag warning 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 warning 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 warning
indicator and any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the RCM and occupant classification system module (OCSM)
using a scan tool.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1723
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1724
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1725
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1726
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1727
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1728
Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1729
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1730
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1731
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1732
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1733
Fuse: Locations Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
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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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Diagram Information and Instructions > Page 1737
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 1738
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Diagram Information and Instructions > Page 1739
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Diagram Information and Instructions > Page 1740
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Diagram Information and Instructions > Page 1741
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Diagram Information and Instructions > Page 1742
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Diagram Information and Instructions > Page 1743
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Diagram Information and Instructions > Page 1744
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Diagram Information and Instructions > Page 1745
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Diagram Information and Instructions > Page 1746
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Diagram Information and Instructions > Page 1747
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
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ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Fuse: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Location
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Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
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Fuse
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Fuse
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Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
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Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
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Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
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Battery Junction Box (BJB) / Power Distribution Box
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Fuse
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Fuse
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ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1760
Battery Junction Box (BJB) / Power Distribution Box
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ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1761
Fuse: Application and ID Auxiliary Relay Box 1
Auxiliary Relay Box 1
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> Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Fuse Block: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Location
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Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
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Fuse
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Fuse
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Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
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Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
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Fuse Block: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
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> Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1772
Battery Junction Box (BJB) / Power Distribution Box
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Fuse
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Fuse
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Battery Junction Box (BJB) / Power Distribution Box
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Fuse Block: Locations Auxiliary Relay Box 1
Auxiliary Relay Box 1
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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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
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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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
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> Diagram Information and Instructions > Page 1780
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
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> Diagram Information and Instructions > Page 1781
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
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> Diagram Information and Instructions > Page 1782
Symbols (Part 2)
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Symbols (Part 3)
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Symbols (Part 4)
Symbols (Part 5)
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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 terminal by pulling each wire at the end of the connector.
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> Diagram Information and Instructions > Page 1786
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
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> Diagram Information and Instructions > Page 1787
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
3 = Splice tape
4 = Harness tape
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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.
3. lnstall 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 seat wire splice.
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> Diagram Information and Instructions > Page 1789
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.
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 6.35mm (1/4 in) 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.
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> Diagram Information and Instructions > Page 1790
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.
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, barrel squeeze tool handles appropriate 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.
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> Diagram Information and Instructions > Page 1791
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
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> Diagram Information and Instructions > Page 1792
Fuse Block: Connector Views
C1035A
C1035B
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C2280A (Part 1)
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> Diagram Information and Instructions > Page 1794
C2280A (Part 2)
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> Diagram Information and Instructions > Page 1795
C2280B
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> Diagram Information and Instructions > Page 1796
C2280C
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> Diagram Information and Instructions > Page 1797
C2280D
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> Diagram Information and Instructions > Page 1798
C2280E
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Fuse Block: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Location
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Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
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Fuse
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Fuse
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Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
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Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
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and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1806
Fuse Block: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
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and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1807
Battery Junction Box (BJB) / Power Distribution Box
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Fuse
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Fuse
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Battery Junction Box (BJB) / Power Distribution Box
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Fuse Block: Application and ID Auxiliary Relay Box 1
Auxiliary Relay Box 1
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Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Relay Box: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Location
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Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1816
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
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Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1817
Fuse
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Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1818
Fuse
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Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1819
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
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Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1820
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
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Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
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Battery Junction Box (BJB) / Power Distribution Box
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Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1823
Fuse
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Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1824
Fuse
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Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1826
Relay Box: Locations Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams >
Battery Junction Box (BJB) > Page 1829
Relay Box: Diagrams Smart Junction Box (SJB)
C2280A (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams >
Battery Junction Box (BJB) > Page 1830
C2280A (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams >
Battery Junction Box (BJB) > Page 1831
C2280B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams >
Battery Junction Box (BJB) > Page 1832
C2280C
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams >
Battery Junction Box (BJB) > Page 1833
C2280D
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams >
Battery Junction Box (BJB) > Page 1834
C2280E
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1837
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1838
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1839
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1840
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1841
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1842
Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1843
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1844
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1845
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1846
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1847
Relay Box: Application and ID Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Testing and Inspection
Low Tire Pressure Indicator: Testing and Inspection
Tire Pressure Monitoring System (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.
Tire Pressure Monitoring System (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.
NOTE: For vehicles with different front and rear tire pressures (such as E-Series and certain
F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the
sensors will result in a false low tire pressure event, which will cause the TPMS indicator to
illuminate.
1. The TPMS indicator remains on continuously for the following 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 the Tire Pressure Monitoring
System (TPMS) Sensor Activation procedure.
Tire Pressure Monitoring System (TPMS) Indicator Flashes
The TPMS indicator flashes for 70 seconds, then remains ON solid when the ignition switch is
turned to the ON position, for the following conditions: 1. Tire Pressure Sensor Fault - If equipped,
the message center will display TIRE PRESSURE 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 not received
any signals from the SJB for more than 5 seconds. If equipped, the message center displays TIRE
PRESSURE 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 PRESSURE
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 (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator >
Component Information > Service and Repair
Maintenance Required Lamp/Indicator: Service and Repair
MESSAGE CENTER CONFIGURATION
Oil Life Reset And Start Value - High Series Instrument Cluster
NOTE: The oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180
days.
1. From the setup menu, press and release the RESET button to display HOLD RESET IF NEW
OIL. 2. Press and hold the RESET button for 2 seconds and release to reset the oil life to 100%. 3.
The message center displays OIL LIFE SET TO 100%. 4. Once the message center displays OIL
LIFE SET TO 100%, release the RESET button then press and release the RESET button to
reduce the start
value (10% for each button press).
Oil Life Reset And Start Value - Base Instrument Cluster
NOTE: Oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days.
- All message center functions are carried out using the single stem reset button in the instrument
cluster.
1. Press and release the SELECT/RESET button to scroll through the information displays until the
message center displays HOLD RESET IF NEW
OIL.
2. Press and hold the SELECT/RESET button for approximately 2 seconds until the message
center displays OIL LIFE SET TO 100%. 3. Once OIL LIFE SET TO 100% is displayed, press and
hold the SELECT/RESET button for more than 2 seconds until the message center displays
OIL LIFE SET TO XXX%.
4. Press and release the SELECT/RESET button to reduce the start value (10% for each button
press). 5. Press and release the SELECT/RESET button to exit the procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and
Operation
Vehicle Lifting: Description and Operation
JACKING AND LIFTING
WARNING:
- Vehicle may have multiple drive wheels. Do not use engine to power the driveline unless all drive
wheels are elevated off the ground. Drive wheels in contact with ground could cause unexpected
vehicle movement. Failure to follow this instruction may result in serious personal injury.
- When jacking or lifting the vehicle, block all wheels remaining on the ground. Set the parking
brake if the rear wheels will remain on the ground. These actions help prevent unintended vehicle
movement. Failure to follow these instructions may result in serious personal injury.
- Never get underneath a vehicle that is supported only by a jack. The jack could unintentionally
lower. Always support vehicle with floor stands. Failure to follow these instructions may result in
serious personal injury.
- Only raise the vehicle when positioned on a hard, level surface. Attempting to raise the vehicle on
an uneven or soft surface may result in vehicle slipping or falling from the jack or jackstand. Failure
to follow this instruction may result in serious personal injury.
- Identify the correct jacking points by locating the triangle stamped into the uni-body sheet metal or
vehicle frame. Raising a vehicle in any other location may result in vehicle shifting or falling. Failure
to follow this instruction may result in serious personal injury.
CAUTION:
- The jack provided with the vehicle is intended to be used in an emergency for changing a deflated
tire. To avoid damage to the vehicle, never use the jack to hoist the vehicle for any other purpose.
- Under no circumstances should the vehicle ever be lifted by the front or rear control arms,
halfshafts or front wheel constant velocity (CV) joints. Severe damage to the vehicle may result.
- Do not attempt to use jack pressure on either the front bumper or the rear bumper of any vehicle.
Damage to bumper covers will occur.
- To prevent possible damage to the underbody, do not drive the vehicle onto the drive-on lift
without first checking for possible interference.
- When raising a vehicle on a twin-post hoist, use care when positioning the vehicle so that the
hoisting forks do not interfere with the suspension components, mounting brackets or stabilizer
mounting brackets, if equipped. In addition, use care in hoist positioning to avoid possible damage
to the axle carrier or rear cover.
- 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.
Jacking Points
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and
Operation > Page 1862
Lifting Points
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure
Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training
Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor
Training
Tire Pressure Monitoring System (TPMS) Sensor Training
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). For additional information, refer to
Tire Pressure Monitoring System (TPMS) Sensor Activation.
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 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 activation tool, attempt to activate the same sensor with
the activation tool. If the sensor still does not respond, move the vehicle to rotate the wheels at
least 1/4 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. NOTE: 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.
6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the
activation tool must remain in place 180 degrees from
the valve stem.
Place the activation tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press
and release the test button on the special tool. The horn will sound briefly to indicate that the tire
pressure sensor has been recognized by the SJB.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure
Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training >
Page 1868
7. Within 2 minutes of the horn sounding, place the 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.
8. 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.
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 IDs trained to the SJB and document them
on the applicable warranty claim.
10. 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.
If the sensors are being trained due to the installation of a new SJB, clear any DTCs and perform
the SJB on-demand self test.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure
Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training >
Page 1869
Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor
Activation
Tire Pressure Monitoring System (TPMS) Sensor Activation
NOTE: The tire pressure sensors will go into a "sleep mode" after 30 minutes of inactivity to
conserve battery power. The sensors do not transmit information while in sleep mode, it will be
necessary to wake them up so they will transmit the latest tire pressure information.
1. Turn the ignition switch to the ON position. 2. Position the tire pressure monitor activation tool
against the LF tire sidewall 180 degrees from the tire valve stem.
3. NOTE: The activation tool will provide feedback in the form of a flashing green light and a beep
sound for each successful response from a tire
pressure sensor.
Press the test button on the activation tool to activate the sensor, activate the sensor at least 2
times.
4. Repeat Steps 2 and 3 for the remaining tires. 5. If the tire pressure monitoring system (TPMS)
indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom
Chart
in Diagnosis and Testing.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Disassembly
WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous
chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes,
flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any
part of the battery is swallowed, contact a physician immediately. When disposing of TPMS
sensors, follow the correct procedures for hazardous material disposal. Failure to follow these
instructions may result in serious personal injury.
NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of
accordingly.
NOTE: 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.
1. CAUTION: The sensor, cradle and strap may 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 may occur.
Using a pocket screwdriver or similar tool, remove the sensor locking clip.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1872
3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to
the sensor may 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 may 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 (V8-4.6L (2008))
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 1873
3. CAUTION: The sensor, cradle and strap may 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 (V8-4.6L (2008))
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 1874
Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and
Cradle
Tire Pressure Monitoring System (TPMS) Strap and Cradle
Disassembly
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1875
WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous
chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes,
flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any
part of the battery is swallowed, contact a physician immediately. When disposing of TPMS
sensors, follow the correct procedures for hazardous material disposal. Failure to follow these
instructions may result in serious personal injury.
NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of
accordingly.
NOTE: 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.
1. Remove the tire pressure monitoring system (TPMS) sensor. For additional information, refer to
Tire Pressure Monitoring System (TPMS) Sensor.
2. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this
instruction may result in serious personal injury.
WARNING: Wear protective gloves when handling components or parts that have pointed or sharp
edges. Failure to follow this instruction may result in serious personal injury.
Remove a factory installed strap in the following 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.
3. To remove a dealer installed strap, turn the worm gear screw until the strap is fully released from
the worm gear.
^ Discard the strap.
4. 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 may 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 (V8-4.6L (2008))
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 1876
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 degrees 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 and
sensor are mounted at the lowest spot
possible to avoid damaging the sensor during wheel and tire disassembly and assembly.
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 lb-inch).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1877
6. CAUTION: The sensor, cradle and strap may 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 (V8-4.6L (2008))
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
Tire Pressure Monitoring System (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.
Tire Pressure Monitoring System (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.
NOTE: For vehicles with different front and rear tire pressures (such as E-Series and certain
F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the
sensors will result in a false low tire pressure event, which will cause the TPMS indicator to
illuminate.
1. The TPMS indicator remains on continuously for the following 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 the Tire Pressure Monitoring
System (TPMS) Sensor Activation procedure.
Tire Pressure Monitoring System (TPMS) Indicator Flashes
The TPMS indicator flashes for 70 seconds, then remains ON solid when the ignition switch is
turned to the ON position, for the following conditions: 1. Tire Pressure Sensor Fault - If equipped,
the message center will display TIRE PRESSURE 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 not received
any signals from the SJB for more than 5 seconds. If equipped, the message center displays TIRE
PRESSURE 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 PRESSURE
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 (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training
Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor
Training
Tire Pressure Monitoring System (TPMS) Sensor Training
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). For additional information, refer to
Tire Pressure Monitoring System (TPMS) Sensor Activation.
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 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 activation tool, attempt to activate the same sensor with
the activation tool. If the sensor still does not respond, move the vehicle to rotate the wheels at
least 1/4 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. NOTE: 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.
6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the
activation tool must remain in place 180 degrees from
the valve stem.
Place the activation tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press
and release the test button on the special tool. The horn will sound briefly to indicate that the tire
pressure sensor has been recognized by the SJB.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 1886
7. Within 2 minutes of the horn sounding, place the 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.
8. 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.
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 IDs trained to the SJB and document them
on the applicable warranty claim.
10. 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.
If the sensors are being trained due to the installation of a new SJB, clear any DTCs and perform
the SJB on-demand self test.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 1887
Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor
Activation
Tire Pressure Monitoring System (TPMS) Sensor Activation
NOTE: The tire pressure sensors will go into a "sleep mode" after 30 minutes of inactivity to
conserve battery power. The sensors do not transmit information while in sleep mode, it will be
necessary to wake them up so they will transmit the latest tire pressure information.
1. Turn the ignition switch to the ON position. 2. Position the tire pressure monitor activation tool
against the LF tire sidewall 180 degrees from the tire valve stem.
3. NOTE: The activation tool will provide feedback in the form of a flashing green light and a beep
sound for each successful response from a tire
pressure sensor.
Press the test button on the activation tool to activate the sensor, activate the sensor at least 2
times.
4. Repeat Steps 2 and 3 for the remaining tires. 5. If the tire pressure monitoring system (TPMS)
indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom
Chart
in Diagnosis and Testing.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Disassembly
WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous
chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes,
flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any
part of the battery is swallowed, contact a physician immediately. When disposing of TPMS
sensors, follow the correct procedures for hazardous material disposal. Failure to follow these
instructions may result in serious personal injury.
NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of
accordingly.
NOTE: 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.
1. CAUTION: The sensor, cradle and strap may 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 may occur.
Using a pocket screwdriver or similar tool, remove the sensor locking clip.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1890
3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to
the sensor may 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 may 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 (V8-4.6L (2008))
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 1891
3. CAUTION: The sensor, cradle and strap may 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 (V8-4.6L (2008))
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 1892
Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and
Cradle
Tire Pressure Monitoring System (TPMS) Strap and Cradle
Disassembly
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1893
WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous
chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes,
flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any
part of the battery is swallowed, contact a physician immediately. When disposing of TPMS
sensors, follow the correct procedures for hazardous material disposal. Failure to follow these
instructions may result in serious personal injury.
NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of
accordingly.
NOTE: 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.
1. Remove the tire pressure monitoring system (TPMS) sensor. For additional information, refer to
Tire Pressure Monitoring System (TPMS) Sensor.
2. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this
instruction may result in serious personal injury.
WARNING: Wear protective gloves when handling components or parts that have pointed or sharp
edges. Failure to follow this instruction may result in serious personal injury.
Remove a factory installed strap in the following 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.
3. To remove a dealer installed strap, turn the worm gear screw until the strap is fully released from
the worm gear.
^ Discard the strap.
4. 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 may 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 (V8-4.6L (2008))
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 1894
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 degrees 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 and
sensor are mounted at the lowest spot
possible to avoid damaging the sensor during wheel and tire disassembly and assembly.
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 lb-inch).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 1895
6. CAUTION: The sensor, cradle and strap may 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 (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest for Wheels: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling
Wheels: Customer Interest Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling
TSB 10-11-2
06/21/10
20 INCH POLISHED ALUMINUM WHEEL - CORROSION AND ETCHING
FORD: 2008-2010 Explorer Sport Trac, Explorer
MERCURY: 2008-2010 Mountaineer
ISSUE Some 2008-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with
20-inch aluminum wheels may exhibit the clear coat peeling off the wheel and/or cracks in the clear
coat that look like spider webs. This may be due to a galvanic corrosion reaction between the
aluminum wheel and the chrome center wheel cap.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Replace the affected wheel or wheels and install new center wheel caps that prevent the corrosion.
1. Inspect wheel(s) for cracked or peeling clear coat. (Figure 1)
NOTE
CONDITIONS ATTRIBUTABLE TO DAMAGE ARE NOT ELIGIBLE FOR COVERAGE UNDER
WARRANTY. REFER TO WARRANTY AND POLICY MANUAL FOR ADDITIONAL
INFORMATION.
2. To service, replace only affected wheel or wheels and install new center wheel caps. Refer to
Workshop Manual, Section 204-04, for wheel removal
and installation procedures including tire/wheel disassembly/assembly to prevent damage to the
tire pressure monitoring system (TPMS) sensor.
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest for Wheels: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling >
Page 1904
101102A 2008-2010 0.6 Hr.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace One Wheel And Center
Wheel Cap (Do Not Use With Any Other Labor Operations)
101102B 2008-2010 0.9 Hr.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Two Wheels And Center
Wheel Caps (Do Not Use With Any Other Labor Operations)
101102C 2008-2010 1.2 Hrs.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Three Wheels And Center
Wheels Caps (Do Not Use With Any Other Labor Operations)
101102D 2008-2010 1.5 Hrs.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Four Wheels And Center
Wheel Caps (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 14
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 1909
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 1914
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 (V8-4.6L (2008))
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 1915
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 1920
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 (V8-4.6L (2008))
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 1921
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 (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat
Cracking/Peeling
Wheels: All Technical Service Bulletins Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling
TSB 10-11-2
06/21/10
20 INCH POLISHED ALUMINUM WHEEL - CORROSION AND ETCHING
FORD: 2008-2010 Explorer Sport Trac, Explorer
MERCURY: 2008-2010 Mountaineer
ISSUE Some 2008-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with
20-inch aluminum wheels may exhibit the clear coat peeling off the wheel and/or cracks in the clear
coat that look like spider webs. This may be due to a galvanic corrosion reaction between the
aluminum wheel and the chrome center wheel cap.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Replace the affected wheel or wheels and install new center wheel caps that prevent the corrosion.
1. Inspect wheel(s) for cracked or peeling clear coat. (Figure 1)
NOTE
CONDITIONS ATTRIBUTABLE TO DAMAGE ARE NOT ELIGIBLE FOR COVERAGE UNDER
WARRANTY. REFER TO WARRANTY AND POLICY MANUAL FOR ADDITIONAL
INFORMATION.
2. To service, replace only affected wheel or wheels and install new center wheel caps. Refer to
Workshop Manual, Section 204-04, for wheel removal
and installation procedures including tire/wheel disassembly/assembly to prevent damage to the
tire pressure monitoring system (TPMS) sensor.
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat
Cracking/Peeling > Page 1927
101102A 2008-2010 0.6 Hr.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace One Wheel And Center
Wheel Cap (Do Not Use With Any Other Labor Operations)
101102B 2008-2010 0.9 Hr.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Two Wheels And Center
Wheel Caps (Do Not Use With Any Other Labor Operations)
101102C 2008-2010 1.2 Hrs.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Three Wheels And Center
Wheels Caps (Do Not Use With Any Other Labor Operations)
101102D 2008-2010 1.5 Hrs.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Four Wheels And Center
Wheel Caps (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 14
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 1932
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 1937
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 (V8-4.6L (2008))
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 1938
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 1943
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 (V8-4.6L (2008))
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 1944
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 (V8-4.6L (2008))
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
Wheel Bearing and Wheel Hub
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure may result in major service expense. New parts must be
installed with the same part numbers or equivalent part, if replacement is 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 and tire.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front > Page 1949
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 lb-ft).
3. Remove the brake disc.
4. NOTE: Inspect and if necessary, clean area around wheel speed sensor before removing it from
the wheel bearing and hub.
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 lb-ft).
5. Remove the 3 bolts and the wheel bearing and wheel hub.
^ Discard the bolts.
^ To install, tighten to 122 Nm (90 lb-ft).
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front > Page 1950
Wheel Bearing: Service and Repair Rear
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 may result in major service expense. New parts must be
installed with the same part numbers or equivalent part, if replacement is 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 lb-inch).
3. Using the special tool and a suitable press, remove the wheel hub.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front > Page 1951
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 (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service
Bulletins > Customer Interest for Wheel Cover: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat
Cracking/Peeling
Wheel Cover: Customer Interest Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling
TSB 10-11-2
06/21/10
20 INCH POLISHED ALUMINUM WHEEL - CORROSION AND ETCHING
FORD: 2008-2010 Explorer Sport Trac, Explorer
MERCURY: 2008-2010 Mountaineer
ISSUE Some 2008-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with
20-inch aluminum wheels may exhibit the clear coat peeling off the wheel and/or cracks in the clear
coat that look like spider webs. This may be due to a galvanic corrosion reaction between the
aluminum wheel and the chrome center wheel cap.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Replace the affected wheel or wheels and install new center wheel caps that prevent the corrosion.
1. Inspect wheel(s) for cracked or peeling clear coat. (Figure 1)
NOTE
CONDITIONS ATTRIBUTABLE TO DAMAGE ARE NOT ELIGIBLE FOR COVERAGE UNDER
WARRANTY. REFER TO WARRANTY AND POLICY MANUAL FOR ADDITIONAL
INFORMATION.
2. To service, replace only affected wheel or wheels and install new center wheel caps. Refer to
Workshop Manual, Section 204-04, for wheel removal
and installation procedures including tire/wheel disassembly/assembly to prevent damage to the
tire pressure monitoring system (TPMS) sensor.
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service
Bulletins > Customer Interest for Wheel Cover: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat
Cracking/Peeling > Page 1960
101102A 2008-2010 0.6 Hr.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace One Wheel And Center
Wheel Cap (Do Not Use With Any Other Labor Operations)
101102B 2008-2010 0.9 Hr.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Two Wheels And Center
Wheel Caps (Do Not Use With Any Other Labor Operations)
101102C 2008-2010 1.2 Hrs.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Three Wheels And Center
Wheels Caps (Do Not Use With Any Other Labor Operations)
101102D 2008-2010 1.5 Hrs.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Four Wheels And Center
Wheel Caps (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 14
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheel Cover: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat
Cracking/Peeling
Wheel Cover: All Technical Service Bulletins Wheels - 20 Inch Wheels Clear Coat
Cracking/Peeling
TSB 10-11-2
06/21/10
20 INCH POLISHED ALUMINUM WHEEL - CORROSION AND ETCHING
FORD: 2008-2010 Explorer Sport Trac, Explorer
MERCURY: 2008-2010 Mountaineer
ISSUE Some 2008-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with
20-inch aluminum wheels may exhibit the clear coat peeling off the wheel and/or cracks in the clear
coat that look like spider webs. This may be due to a galvanic corrosion reaction between the
aluminum wheel and the chrome center wheel cap.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Replace the affected wheel or wheels and install new center wheel caps that prevent the corrosion.
1. Inspect wheel(s) for cracked or peeling clear coat. (Figure 1)
NOTE
CONDITIONS ATTRIBUTABLE TO DAMAGE ARE NOT ELIGIBLE FOR COVERAGE UNDER
WARRANTY. REFER TO WARRANTY AND POLICY MANUAL FOR ADDITIONAL
INFORMATION.
2. To service, replace only affected wheel or wheels and install new center wheel caps. Refer to
Workshop Manual, Section 204-04, for wheel removal
and installation procedures including tire/wheel disassembly/assembly to prevent damage to the
tire pressure monitoring system (TPMS) sensor.
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheel Cover: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat
Cracking/Peeling > Page 1966
101102A 2008-2010 0.6 Hr.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace One Wheel And Center
Wheel Cap (Do Not Use With Any Other Labor Operations)
101102B 2008-2010 0.9 Hr.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Two Wheels And Center
Wheel Caps (Do Not Use With Any Other Labor Operations)
101102C 2008-2010 1.2 Hrs.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Three Wheels And Center
Wheels Caps (Do Not Use With Any Other Labor Operations)
101102D 2008-2010 1.5 Hrs.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Four Wheels And Center
Wheel Caps (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 14
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information >
Specifications > Rear Axle Wheel End Nut
Axle Nut: Specifications Rear Axle Wheel End Nut
Rear Axle Wheel End Nut ....................................................................................................................
................................................ 275 Nm (203 lb-ft).
Discard the wheel end nut.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information >
Specifications > Rear Axle Wheel End Nut > Page 1972
Axle Nut: Specifications Rear Axle Halfshaft Nut
Rear Axle Halfshaft Nut .......................................................................................................................
................................................ 275 Nm (203 lb-ft).
Install a new halfshaft nut and washer.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications
Wheel Fastener: Specifications
Wheel Lug Nuts
...........................................................................................................................................................
135 Nm (100 lb-ft). in a star pattern
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front
Wheel Fastener: Service and Repair Front
Wheel Studs
Removal
1. Remove the wheel and tire.
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 165 Nm (122 lb-ft).
3. Remove the brake disc. 4. Using the special tool, remove the wheel stud.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front > Page 1978
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 (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front > Page 1979
Wheel Fastener: Service and Repair Rear
Wheel Studs
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front > Page 1980
Removal
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure may result in major service expense. New parts must be
installed with the same part numbers or equivalent part, if replacement is 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, or incorrect clamp load and
component damage may occur.
1. Remove the wheel and tire.
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. NOTE: 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 (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front > Page 1981
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 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation
Vehicle Lifting: Description and Operation
JACKING AND LIFTING
WARNING:
- Vehicle may have multiple drive wheels. Do not use engine to power the driveline unless all drive
wheels are elevated off the ground. Drive wheels in contact with ground could cause unexpected
vehicle movement. Failure to follow this instruction may result in serious personal injury.
- When jacking or lifting the vehicle, block all wheels remaining on the ground. Set the parking
brake if the rear wheels will remain on the ground. These actions help prevent unintended vehicle
movement. Failure to follow these instructions may result in serious personal injury.
- Never get underneath a vehicle that is supported only by a jack. The jack could unintentionally
lower. Always support vehicle with floor stands. Failure to follow these instructions may result in
serious personal injury.
- Only raise the vehicle when positioned on a hard, level surface. Attempting to raise the vehicle on
an uneven or soft surface may result in vehicle slipping or falling from the jack or jackstand. Failure
to follow this instruction may result in serious personal injury.
- Identify the correct jacking points by locating the triangle stamped into the uni-body sheet metal or
vehicle frame. Raising a vehicle in any other location may result in vehicle shifting or falling. Failure
to follow this instruction may result in serious personal injury.
CAUTION:
- The jack provided with the vehicle is intended to be used in an emergency for changing a deflated
tire. To avoid damage to the vehicle, never use the jack to hoist the vehicle for any other purpose.
- Under no circumstances should the vehicle ever be lifted by the front or rear control arms,
halfshafts or front wheel constant velocity (CV) joints. Severe damage to the vehicle may result.
- Do not attempt to use jack pressure on either the front bumper or the rear bumper of any vehicle.
Damage to bumper covers will occur.
- To prevent possible damage to the underbody, do not drive the vehicle onto the drive-on lift
without first checking for possible interference.
- When raising a vehicle on a twin-post hoist, use care when positioning the vehicle so that the
hoisting forks do not interfere with the suspension components, mounting brackets or stabilizer
mounting brackets, if equipped. In addition, use care in hoist positioning to avoid possible damage
to the axle carrier or rear cover.
- 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.
Jacking Points
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation > Page
1985
Lifting Points
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 1993
C1452
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Diagrams > Page 1994
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 (CKP) sensor 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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Diagrams > Page 1995
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.
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 (V8-4.6L (2008))
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 variable camshaft timing (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 (V8-4.6L (2008))
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.
Compression Pressure Limit Chart (Part 1)
Compression Pressure Limit Chart (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications > Page 2002
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 (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications > Page 2003
Compression Pressure Limit Chart (Part 2)
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
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 (V8-4.6L (2008))
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 ...............................................................................................................
.................................................... 10 Nm (89 lb-in).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft
Gear/Sprocket > Component Information > Service and Repair
Camshaft Gear/Sprocket: Service and Repair
Camshaft Phaser and Sprocket
Valve Train Components - Exploded View (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft
Gear/Sprocket > Component Information > Service and Repair > Page 2011
Valve Train Components - Exploded View (Part 2)
Removal
1. If servicing the RH camshaft phaser and sprocket, remove the RH camshaft. 2. If servicing the
LH camshaft phaser and sprocket, remove the LH camshaft.
3. CAUTION: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
NOTE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the special
tool is removed or out of placement, the engine front cover must be removed and the engine must
be retimed.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft
Gear/Sprocket > Component Information > Service and Repair > Page 2012
Remove the camshaft phaser and sprocket from the timing chain.
4. Inspect the front of the camshaft phaser and sprocket for missing or damaged roll pins.
^ If the roll pins are missing or damaged, a new camshaft phaser and sprocket must be installed.
5. Inspect the rear of the camshaft phaser and sprocket for a deformed or damaged location pin.
^ If the location pin is deformed or damaged, a new camshaft phaser and sprocket must be
installed.
6. Visually inspect the camshaft phaser and sprocket for squareness (A). If the trigger wheel or
spring is deformed or damaged (B), install a new
camshaft phaser and sprocket.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft
Gear/Sprocket > Component Information > Service and Repair > Page 2013
Installation
1. CAUTION: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
If installing a new camshaft phaser and sprocket, transfer the original scribe mark to the new
camshaft phaser and sprocket.
2. CAUTION: The timing chain must be installed in its original position onto the camshaft phaser
and sprocket using the scribed marks, or
damage to valves and pistons will result.
CAUTION: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
Align the scribe marks and position the camshaft phaser and sprocket into the timing chain.
3. If servicing the RH camshaft phaser and sprocket, install the RH camshaft. 4. If servicing the LH
camshaft phaser and sprocket, install the LH camshaft.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures
Camshaft: Procedures
Camshaft Bearing Journal Diameter
1. Measure each camshaft journal diameter in 2 directions.
Camshaft Journal to Bearing Clearance - OHC Engines
1. NOTE: The camshaft journals must meet specifications before checking camshaft journal
clearance.
Measure each camshaft bearing in 2 directions. ^
Subtract the camshaft journal diameter from the camshaft bearing diameter.
Camshaft End Play - OHC Engines
1. Using the special tool, measure the camshaft end play. 2. Position the camshaft to the rear of
the cylinder head. 3. Zero the indicator. 4. Move the camshaft to the front of the cylinder head. Note
and record the camshaft end play.
^ If camshaft end play exceeds specifications, install a 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 (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 2018
Camshaft Surface Inspection
1. Inspect camshaft lobes for pitting or damage in the contact area. Minor pitting is acceptable
outside the contact area.
Camshaft Lobe Lift
1. Use an indicator gauge 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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 2019
1. NOTE: Camshaft journals must be within specifications before checking runout.
Using the special tool, measure the camshaft runout. ^
Rotate the camshaft and subtract the lowest indicator reading from the highest indicator reading.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 2020
Camshaft: Removal and Replacement
Camshaft - LH
Camshaft - LH
Valve Train Components - Exploded View (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 2021
Valve Train Components - Exploded View (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 2022
Removal
CAUTION: The camshaft procedure must be followed exactly or damage to the valves and pistons
will result.
1. Position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation
at the 1 o'clock position.
2. Remove the LH valve cover.
3. CAUTION: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
Loosen and back off the LH camshaft phaser and sprocket bolt one full turn.
4. Disconnect the LH camshaft position (CMP) sensor electrical connector.
5. Remove the LH CMP sensor and the bolt.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 2023
6. NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft keyway will
require one full additional rotation to 12 o'clock.
The No. 5 cylinder camshaft lobe must be coming up on the exhaust stroke. Verify by noting the
position of the 2 intake camshaft lobes and the exhaust lobe on the No. 5 cylinder.
7. Remove only the 3 camshaft roller followers shown in the illustration.
8. CAUTION: The camshaft roller followers must be installed in their original locations. Record
camshaft roller follower locations. Failure
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 2024
to follow these instructions may result in engine damage.
NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If
a valve drops into the cylinder, the cylinder head must be removed.
NOTE: It may be necessary to push the valve down while compressing the spring.
Using the special tool, remove only the 3 designated camshaft roller followers from the previous
step.
9. CAUTION: The crankshaft cannot be moved past the 6 o'clock position once set or engine
damage may occur.
Rotate the crankshaft clockwise, as viewed from the front, positioning the crankshaft damper spoke
at the 6 o'clock position and the timing mark indentation at the 7 o'clock position.
10. CAUTION: Engine is not freewheeling. Camshaft procedure must be followed exactly or
damage to valves and pistons will result.
NOTE: The Timing Chain Wedge tool must be installed square to the timing chain and the engine
block.
NOTE: Engine front cover removed for clarity.
Install the special tool in the LH timing chain as shown.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 2025
11. CAUTION: Do not remove the Timing Chain Wedge tool at any time during assembly. If the
special tool is removed or out of placement,
the engine front cover must be removed and the engine must be retimed.
CAUTION: The timing chain must be installed in its original position onto the camshaft phaser and
sprocket using the scribed marks, or damage to valves and pistons will result.
NOTE: RH shown, LH similar.
Scribe a location mark on the timing chain and the camshaft phaser and sprocket assembly.
12. CAUTION: Remove the front thrust camshaft bearing cap straight upward from the bearing
towers or the bearing cap may be damaged
from side loading.
Remove the 2 bolts and the LH cylinder head camshaft front bearing cap.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 2026
13. CAUTION: The camshaft bearing caps must be installed in their original locations. Record
camshaft bearing cap locations. Failure to
follow these instructions may result in engine damage.
Remove the remaining bolts in the sequence shown and remove the LH cylinder head camshaft
bearing caps.
14. Clean and inspect the LH camshaft bearing caps.
^ The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is
free of foreign material.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 2027
15. CAUTION: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
CAUTION: Only use hand tools to remove the camshaft phaser and sprocket bolt or damage may
occur to the camshaft or camshaft phaser and sprocket.
CAUTION: Do not remove the Timing Chain Wedge tool at any time during assembly. If the special
tool is removed or out of placement, the engine front cover must be removed and the engine must
be retimed.
Remove the bolt and withdraw the camshaft from the camshaft phaser and sprocket assembly,
leaving the camshaft phaser and sprocket assembly in place. ^
Discard the bolt and washer.
16. Inspect the camshaft phaser and sprocket for damage.
Installation
1. Lubricate the camshaft and camshaft journals with clean engine oil.
2. CAUTION: Do not remove the Timing Chain Wedge tool at any time during assembly. If the
special tool is removed or out of placement,
the engine front cover must be removed and the engine must be retimed.
CAUTION: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
NOTE: Do not allow the camshaft roller followers to move out of position when installing the
camshaft.
Install the camshaft into the camshaft phaser and sprocket assembly and onto the head. Install a
new camshaft phaser and sprocket bolt finger-tight.
3. CAUTION: Do not remove the Timing Chain Wedge tool at any time during assembly. If the
special tool is removed or out of placement,
the engine front cover must be removed and the engine must be retimed.
CAUTION: The timing chain must be installed in its original position onto the camshaft phaser and
sprocket using the scribed marks, or damage to valves and pistons will result.
NOTE: RH shown, LH similar.
Verify the camshaft phaser and sprocket and timing chain scribe marks are still in alignment.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 2028
4. NOTE: Do not allow the camshaft roller followers to move out of position when installing the
camshaft.
Install the camshaft bearing caps in their original locations. ^
Lubricate the camshaft bearing caps with clean engine oil.
^ Position the front camshaft bearing cap.
^ Position the remaining camshaft bearing caps.
^ Install the bolts loosely.
5. Tighten the bolts in the sequence shown.
^ Tighten to 10 Nm (89 lb-in).
6. NOTE: Engine front cover removed for clarity.
Remove the special tools.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 2029
7. Rotate the crankshaft a half turn counterclockwise and position the crankshaft damper spoke at
the 12 o'clock position and the timing mark
indentation at the 1 o'clock position.
8. Verify correct camshaft position by noting the position of the No. 5 cylinder intake and exhaust
camshaft lobes.
9. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the
cylinder. If a valve drops into the cylinder, the
cylinder head must be removed.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 2030
NOTE: It may be necessary to push the valve down while compressing the spring.
Using the special tool, install the 3 originally removed camshaft roller followers.
10. Install the CMP sensor and the bolt.
11. Connect the CMP electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 2031
12. CAUTION: Only use hand tools to install the camshaft phaser and sprocket assembly or
damage may occur to the camshaft or camshaft
phaser and sprocket.
CAUTION: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
Tighten the camshaft phaser and sprocket bolt in 2 stages: ^
Stage 1: Tighten to 40 Nm (30 lb-ft).
^ Stage 2: Tighten an additional 90 degrees.
13. Install the LH valve cover.
Camshaft - RH
Camshaft - RH
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 2032
Valve Train Components - Exploded View (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 2033
Valve Train Components - Exploded View (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 2034
Removal
CAUTION: The camshaft procedure must be followed exactly or damage to the valves and pistons
will result.
1. Position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation
at the 1 o'clock position.
2. Remove the RH valve cover.
3. CAUTION: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
Loosen and backoff the RH camshaft phaser and sprocket bolt one full turn.
4. Disconnect the RH camshaft position (CMP) sensor electrical connector.
5. Remove the bolt and the RH CMP sensor.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 2035
6. NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft will require one
full additional rotation to 12 o'clock.
The No. 1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by
noting the position of the 2 intake camshaft lobes and the exhaust lobe on the No. 1 cylinder.
7. Remove only the 3 camshaft roller followers shown in the illustration.
8. CAUTION: The camshaft roller followers must be installed in their original locations. Record
camshaft roller follower locations. Failure
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 2036
to follow these instructions may result in engine damage.
NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If
a valve drops into the cylinder, the cylinder head must be removed.
NOTE: It may be necessary to push the valve down while compressing the spring.
Using the special tool, remove only the 3 designated camshaft roller followers from the previous
step.
9. CAUTION: The crankshaft cannot be moved past the 6 o'clock position once set or engine
damage may occur.
Rotate the crankshaft clockwise, as viewed from the front, positioning the crankshaft damper spoke
at the 6 o'clock position and the timing mark indentation at the 7 o'clock position.
10. CAUTION: Engine is not freewheeling. Camshaft procedure must be followed exactly or
damage to valves and pistons will result.
NOTE: The Timing Chain Wedge tool must be installed square to the timing chain and the engine
block.
NOTE: Engine front cover removed for clarity.
Install the special tool in the RH timing chain as shown.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 2037
11. CAUTION: Do not remove the Timing Chain Wedge tool at any time during assembly. If the
special tool is removed or out of placement,
the engine front cover must be removed and the engine must be retimed.
CAUTION: The timing chain must be installed in its original position onto the camshaft phaser and
sprocket using the scribed marks, or damage to valves and pistons will result.
Scribe a location mark on the timing chain and the camshaft phaser and sprocket assembly.
12. CAUTION: Remove the front thrust camshaft bearing cap straight upward from the bearing
towers or the bearing cap may be damaged
from side loading.
Remove the 2 bolts and the RH cylinder head camshaft front bearing cap.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 2038
13. CAUTION: The camshaft bearing caps must be installed in their original locations. Record
camshaft bearing cap locations. Failure to
follow these instructions may result in engine damage.
Remove the remaining bolts in the sequence shown and remove the RH cylinder head camshaft
bearing caps.
14. Clean and inspect the RH camshaft bearing caps.
^ The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is
free of foreign material.
15. CAUTION: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 2039
CAUTION: Only use hand tools to remove the camshaft phaser and sprocket bolt or damage may
occur to the camshaft or camshaft phaser and sprocket.
CAUTION: Do not remove the Timing Chain Wedge tool at any time during assembly. If the special
tool is removed or out of placement, the engine front cover must be removed and the engine must
be retimed.
Remove the bolt and withdraw the camshaft from the camshaft phaser and sprocket assembly,
leaving the camshaft phaser and sprocket assembly in place. ^
Discard the bolt and washer.
16. Inspect the camshaft phaser and sprocket for damage.
Installation
1. Lubricate the camshaft and camshaft journals with clean engine oil.
2. CAUTION: Do not remove the Timing Chain Wedge tool at any time during assembly. If the
special tool is removed or out of placement,
the engine front cover must be removed and the engine must be retimed.
CAUTION: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
NOTE: Do not allow the camshaft roller followers to move out of position when installing the
camshaft.
Install the camshaft into the camshaft phaser and sprocket assembly and onto the head. Install a
new camshaft phaser and sprocket bolt finger-tight.
3. CAUTION: Do not remove the Timing Chain Wedge tool at any time during assembly. If the
special tool is removed or out of placement,
the engine front cover must be removed and the engine must be retimed.
CAUTION: The timing chain must be installed in its original position onto the camshaft phaser and
sprocket using the scribed marks, or damage to valves and pistons will result.
Verify the camshaft phaser and sprocket and timing chain scribe marks are still in alignment.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 2040
4. NOTE: Do not allow the camshaft roller followers to move out of position when installing the
camshaft.
Install the camshaft bearing caps in their original locations. ^
Lubricate the camshaft bearing caps with clean engine oil.
^ Position the front camshaft bearing cap.
^ Position the remaining camshaft bearing caps.
^ Install the bolts loosely.
5. Tighten the bolts in the sequence shown.
^ Tighten to 10 Nm (89 lb-in).
6. NOTE: Engine front cover removed for clarity.
Remove the special tool.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 2041
7. Rotate the crankshaft a half turn counterclockwise and position the crankshaft damper spoke at
the 12 o'clock position and the timing mark
indentation at the 1 o'clock position.
8. Verify correct camshaft position by noting the position of the No. 1 cylinder intake and exhaust
camshaft lobes.
9. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the
cylinder. If a valve drops into the cylinder, the
cylinder head must be removed.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 2042
NOTE: It may be necessary to push the valve down while compressing the spring.
Using the special tool, install the 3 originally removed camshaft roller followers.
10. Install the CMP sensor and the bolt.
^ Tighten to 10 Nm (89 lb-in).
11. Connect the CMP electrical connector.
12. CAUTION: Only use hand tools to install the camshaft phaser and sprocket assembly or
damage may occur to the camshaft or camshaft
phaser and sprocket.
CAUTION: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
Tighten the new camshaft phaser and sprocket bolt in 2 stages: ^
Stage 1: Tighten to 40 Nm (30 lb-ft).
^ Stage 2: Tighten an additional 90 degrees.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures > Page 2043
13. Install the RH valve cover.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Hydraulic Lash Adjuster Inspection
1. Inspect the hydraulic lash adjuster and roller follower for damage. If any damage is found,
inspect the camshaft lobes and valves for damage.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Testing and Inspection > Page 2047
Lifter / Lash Adjuster: Service and Repair
Hydraulic Lash Adjuster
Removal and Installation
1. Remove the camshafts. 2. Remove the remaining roller followers from the cylinder head being
serviced.
3. CAUTION: If the components are to be reinstalled, they must be installed in their original
positions. Mark the components for
installation into their original locations. Failure to follow these instructions may result in engine
damage.
Remove the hydraulic lash adjusters that are being serviced.
4. Inspect the hydraulic lash adjusters.
5. NOTE: Lubricate each of the hydraulic lash adjusters with clean engine oil prior to installation.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Testing and Inspection
Rocker Arm Assembly: Testing and Inspection
Roller Follower Inspection
1. Inspect the roller follower for flat spots or scoring. If any damage is found, inspect the camshaft
lobes and hydraulic lash adjuster for damage.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Testing and Inspection > Page 2051
Rocker Arm Assembly: Service and Repair
Camshaft Roller Follower
Valve Train Components - Exploded View (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Testing and Inspection > Page 2052
Valve Train Components - Exploded View (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Testing and Inspection > Page 2053
Removal
1. Depending on the roller follower being serviced, remove the LH or RH valve cover. 2. Rotate the
crankshaft until the piston for the valve being serviced is at the top of its stroke with the intake valve
and the exhaust valves closed.
3. CAUTION: If the components are to be reinstalled, they must be installed in their original
positions. Mark the components for
installation into their original locations. Failure to follow these instructions may result in engine
damage.
NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder.
If a valve drops into the cylinder, the cylinder head must be removed.
NOTE: It may be necessary to push the valve down while compressing the spring.
Using the special tool, compress the valve spring and remove the camshaft roller follower.
4. Repeat the previous 2 steps for each roller follower being serviced. 5. Inspect the roller follower.
Installation
1. CAUTION: If the components are to be reinstalled, they must be installed in their original
positions. Mark the components for
installation into their original locations. Failure to follow these instructions may result in engine
damage.
NOTE: Lubricate the roller follower with clean engine oil.
Using the special tool, compress the valve spring and install the camshaft roller follower.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Testing and Inspection > Page 2054
2. Repeat the previous step for each roller follower being serviced. 3. Depending on the valve
being serviced, install the LH or RH valve cover.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 2059
C1452
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Diagrams > Page 2060
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 (CKP) sensor 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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Diagrams > Page 2061
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.
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 (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing >
Component Information > Specifications
Connecting Rod Bearing: Specifications
Connecting Rod
Bearing bore diameter (with assembled liners)
...................................................................................................... 53.049-53.027 mm
(2.0885-2.0877 in) Bearing-to-crankshaft clearance
................................................................................................................................. 0.024-0.066 mm
(0.0009-0.0026 in) Side clearance ......................................................................................................
.................................................................. 0.5-0.15 mm (0.02-0.006 in)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing >
Component Information > Specifications > Page 2066
Connecting Rod Bearing: Testing and Inspection
Bearing Inspection
1. Inspect bearings for the following defects:
1 Cratering - fatigue failure
2 Spot polishing - incorrect seating
3 Imbedded dirty 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 (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing >
Component Information > Specifications > Page 2067
Connecting Rod Bearing: Service and Repair
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Specifications
Connecting Rod: Specifications
Connecting Rod Cap Bolts
Discard the bolts.
First pass .............................................................................................................................................
.................................................... 43 Nm (32 lb-ft). Final pass ............................................................
..................................................................................................................... Tighten an additional
105°
Connecting Rod
Clearance-to-pin
.........................................................................................................................................................
0.009-0.023 mm (0.0004-0.0009 in) Pin bore diameter
...................................................................................................................................................
22.012-22.024 mm (0.8666-0.8671 in) Length (center-to-center) .......................................................
............................................................................................................. 150.7 mm (5.933 in)
Maximum allowed bend .......................................................................................................................
......................................... ± 0.038 mm (0.0015 in) Maximum allowed twist (a)
............................................................................................................................................................
± 0.05 mm (0.0020 in) Bearing bore diameter (with assembled liners)
...................................................................................................... 53.049-53.027 mm
(2.0885-2.0877 in) Bearing-to-crankshaft clearance
................................................................................................................................. 0.024-0.066 mm
(0.0009-0.0026 in) Side clearance ......................................................................................................
.................................................................. 0.5-0.15 mm (0.02-0.006 in) (a) The pin bore and crank
bearing bore must be parallel and in the same vertical plane within the specified total difference
when measured at the ends of a 203 mm bar, 105.5 mm on each side of rod centerline.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Specifications > Page 2071
Connecting Rod: Service and Repair
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
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.
Connecting Rod to Crankshaft Side Clearance
1. Measure the clearance between the connecting rod and the crankshaft. Verify the measurement
is within specification.
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 (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Specifications > Page 2072
2. Measure the telescoping gauge with a micrometer. Verify the diameter is within specification.
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.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Specifications > Page 2073
Connecting Rod-to-Piston Clearance
1. Measure the clearance between the connecting rod and the piston. Verify the measurement is
within specification.
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(R) 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(R) to get the connecting rod bearing journal clearance. The
Plastigage(R) should be smooth and flat. A changing width
indicates a tapered or damaged connecting rod or connecting rod bearing.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Specifications > Page 2074
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket >
Component Information > Specifications
Crankshaft Gear/Sprocket: Specifications
Crankshaft Pulley Bolt
Discard the crankshaft pulley bolt and washer.
First pass .............................................................................................................................................
.................................................... 90 Nm (66 lb-ft). Second pass ........................................................
............................................................................................................................................ Loosen
360° Third pass ...................................................................................................................................
............................................................ 50 Nm (37 lb-ft). Final pass ....................................................
............................................................................................................................... Tighten an
additional 90°
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing >
Component Information > Specifications
Crankshaft Main Bearing: Specifications
Vertical Main Bearing Cap Fasteners
Discard the fasteners.
First pass .............................................................................................................................................
.................................................... 40 Nm (30 lb-ft). Final pass ............................................................
....................................................................................................................... Tighten an additional
90°
Jack Screws
Discard the screws.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing >
Component Information > Specifications > Page 2081
First pass .............................................................................................................................................
..................................................... 5 Nm (44 lb-in). Final pass ............................................................
.................................................................................................................................... 10 Nm (89
lb-in).
Side Bolts ............................................................................................................................................
....................................................... 21 Nm (15 lb-ft).
Discard the bolts.
Crankshaft
Main bearing journal
Diameter
..........................................................................................................................................................
67.481-67.505 mm (2.6567-2.6576 in)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing >
Component Information > Specifications > Page 2082
Maximum taper ....................................................................................................................................
...................................... 0.004 mm (0.0002 in) Maximum out-of-round
....................................................................................................................... 0.0075 mm (0.0003 in)
between cross sections Clearance-to-cylinder block
................................................................................................................................. 0.048-0.024 mm
(0.0019-0.0009 in)
Connecting rod journal
Diameter
..........................................................................................................................................................
53.003-52.983 mm (2.0867-2.0859 in) Maximum taper ......................................................................
.................................................................................................... 0.004 mm (0.0002 in) Maximum
out-of-round ....................................................................................................................... 0.0075
mm (0.0003 in) between cross sections
Maximum end play
....................................................................................................................................................
0.075-0.377 mm (0.0030-0.0148 in) Main bearing bore inside diameter
............................................................................................................................. 72.400-72.424 mm
(2.850-2.851 in)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing >
Component Information > Specifications > Page 2083
Crankshaft Main Bearing: Testing and Inspection
Bearing Inspection
1. Inspect bearings for the following defects:
1 Cratering - fatigue failure
2 Spot polishing - incorrect seating
3 Imbedded dirty 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 (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications
Crankshaft: Specifications
Crankshaft
Main bearing journal
Diameter
..........................................................................................................................................................
67.481-67.505 mm (2.6567-2.6576 in) Maximum taper ......................................................................
.................................................................................................... 0.004 mm (0.0002 in) Maximum
out-of-round ....................................................................................................................... 0.0075
mm (0.0003 in) between cross sections Clearance-to-cylinder block
................................................................................................................................. 0.048-0.024 mm
(0.0019-0.0009 in)
Connecting rod journal
Diameter
..........................................................................................................................................................
53.003-52.983 mm (2.0867-2.0859 in) Maximum taper ......................................................................
.................................................................................................... 0.004 mm (0.0002 in) Maximum
out-of-round ....................................................................................................................... 0.0075
mm (0.0003 in) between cross sections
Maximum end play
....................................................................................................................................................
0.075-0.377 mm (0.0030-0.0148 in) Main bearing bore inside diameter
............................................................................................................................. 72.400-72.424 mm
(2.850-2.851 in)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications > Page 2087
Crankshaft: Service and Repair
Crankshaft Main Bearing Journal Diameter
1. Measure each of the crankshaft main bearing journal diameters in at least 2 directions.
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.
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(R) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications > Page 2088
Crankshaft End Play
1. Using the Dial Indicator Gauge, measure the 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.
Crankshaft Runout
1. NOTE: Crankshaft main bearing journals must be within specifications before checking runout.
Use the Dial Indicator Gauge 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications > Page 2089
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
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. NOTE: 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 4 Nm (35 lb-in).
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 the cable may be damaged.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications
Harmonic Balancer - Crankshaft Pulley: Specifications
Crankshaft Pulley Bolt
Discard the crankshaft pulley bolt and washer.
First pass .............................................................................................................................................
.................................................... 90 Nm (66 lb-ft). Second pass ........................................................
............................................................................................................................................ Loosen
360° Third pass ...................................................................................................................................
............................................................ 50 Nm (37 lb-ft). Final pass ....................................................
............................................................................................................................... Tighten an
additional 90°
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2096
Harmonic Balancer - Crankshaft Pulley: Service and Repair
Crankshaft Pulley
Lower End Components - Exploded View, Crankshaft Pulley and Crankshaft Front Seal
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2097
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair. 2. Remove the cooling fan shroud. For additional information,
refer to Cooling System. 3. Remove the accessory drive belt. For additional information, refer to
Drive Belts, Mounts, Brackets and Accessories. 4. Remove and discard the crankshaft pulley bolt
and washer. 5. Using the special tool, remove the crankshaft pulley.
Installation
1. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area
cleaned with metal surface prep and silicone gasket
remover. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to
follow this procedure can cause future oil leakage.
Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley.
2. Using the special tool, install the crankshaft pulley.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2098
3. Using a new crankshaft pulley bolt, install the bolt and washer and tighten the bolt in 4 stages.
^ Stage 1: Tighten to 90 Nm (66 lb-ft).
^ Stage 2: Loosen 360 degrees.
^ Stage 3: Tighten to 50 Nm (37 lb-ft).
^ Stage 4: Tighten an additional 90 degrees.
4. Install the accessory drive belt. 5. Install the cooling fan shroud.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Specifications
Piston: Specifications
Piston
Diameter (at right angle to pin bore) (uncoated)
Grade 1
............................................................................................................................................................
90.182-90.167 mm (3.5504-3.5499 in) Grade 2
.............................................................................................................................................................
90.196-90.179 mm (3.551-3.5503 in) Grade 3
.............................................................................................................................................................
90.208-90.193 mm (3.5515-3.551 in)
Clearance-to-cylinder bore (at grade size)
................................................................................................................. 0.017-0.047 mm
(0.0007-0.0019 in) Ring end gap
Top ......................................................................................................................................................
......................... 0.15-0.30 mm (0.006-0.012 in) Intermediate
.............................................................................................................................................................
0.25-0.50 mm (0.0098-0.0197 in) Oil control .......................................................................................
......................................................................... 0.15-0.65 mm (0.0059-0.0256 in)
Ring groove width
Top ......................................................................................................................................................
..................... 1.52-1.54 mm (0.0598-0.0606 in) Intermediate
.............................................................................................................................................................
1.52-1.54 mm (0.0598-0.0606 in) Oil control
............................................................................................................................................................
3.030-3.056 mm (0.1193-0.1203 in)
Ring width
Top and intermediate
...............................................................................................................................................
1.50-1.48 mm (0.0590-0.0582 in)
Ring-to-groove clearance
Top ......................................................................................................................................................
................. 0.020-0.060 mm (0.0008-0.0020 in) Intermediate
.........................................................................................................................................................
0.020-0.060 mm (0.0008-0.0020 in)
Pin bore diameter
...............................................................................................................................................
22.0125-22.0175 mm (0.8666-0.8668 in) Pin
Diameter
......................................................................................................................................................
22.0010-22.0030 mm (0.8662-0.8663 in) Length ................................................................................
............................................................................................................. 61.8 mm (2.433 in)
Fit-to-piston
.......................................................................................................................................................
0.0095-0.023 mm (0.0004-0.0009 in)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Procedures
Piston: Procedures
Piston Inspection
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 Bore Diameter
1. WARNING: Since the retainer ring has a tendency to spring out, cover the end of the pin bore
with a hand or shop rag when removing
the ring. Wear eye protection. Failure to follow these instructions may result in serious 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Procedures > Page 2104
Piston Diameter
1. Measure the piston diameter 90 degrees from the piston pin and 42 mm (1.65 in) down from the
top of the piston at the point indicated.
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
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 (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Procedures > Page 2105
2. NOTE: For precision fit, new pistons are divided into 3 categories within each size range based
on their relative position within the range. A paint
spot or specific size grade on a new piston indicates the position within the size range.
Choose the piston with the correct paint color or specific size grade.
Piston Ring End Gap
CAUTION: Use care when fitting piston rings to avoid possible damage to the piston ring or the
cylinder bore.
NOTE: Piston rings should not be transferred from one piston to another.
NOTE: The 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 (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Procedures > Page 2106
Piston Ring-to-Groove Clearance
1. Inspect the piston for ring land damage or accelerated wear.
2. Measure the piston ring-to-groove clearance.
Piston Pin Diameter
1. Measure the piston pin diameter in 2 directions at the points shown. Verify the diameter is within
specification.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Procedures > Page 2107
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Procedures > Page 2108
Piston: Overhaul
Piston
Disassembly
1. Remove the piston rings from the piston.
^ Discard the piston rings.
2. Remove the piston pin retainers and the piston pin. 3. Separate the piston from the connecting
rod. 4. Clean and inspect the piston and connecting rod.
Assembly
1. NOTE: The connecting rod must be installed into the piston with identification markings toward
the front.
Position the connecting rod in the piston.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Procedures > Page 2109
2. Lubricate the piston pin and pin bore with clean engine oil. 3. Install the piston pin in the piston
and connecting rod assembly. 4. Install the piston pin retaining clips in the piston. 5. Lubricate the
piston and the new piston rings with clean engine oil. 6. Install the piston rings onto the piston.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine >
Component Information > Specifications
Piston Ring: Specifications
Piston Rings
End gap
Top ......................................................................................................................................................
......................... 0.15-0.30 mm (0.006-0.012 in) Intermediate
.............................................................................................................................................................
0.25-0.50 mm (0.0098-0.0197 in) Oil control .......................................................................................
......................................................................... 0.15-0.65 mm (0.0059-0.0256 in)
Ring groove width
Top ......................................................................................................................................................
..................... 1.52-1.54 mm (0.0598-0.0606 in) Intermediate
.............................................................................................................................................................
1.52-1.54 mm (0.0598-0.0606 in) Oil control
............................................................................................................................................................
3.030-3.056 mm (0.1193-0.1203 in)
Ring width
Top and intermediate
...............................................................................................................................................
1.50-1.48 mm (0.0590-0.0582 in)
Ring-to-groove clearance
Top ......................................................................................................................................................
................. 0.020-0.060 mm (0.0008-0.0020 in) Intermediate
.........................................................................................................................................................
0.020-0.060 mm (0.0008-0.0020 in)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System
Information > Specifications
Valve Clearance: Specifications
Valve Clearance
This engine is equipped with hydraulic lash adjusters. No adjustment is required.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious personal injury.
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the
fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under
high pressure, even when the engine is not running. Failure to follow this instruction may result in
serious 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 (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Testing and Inspection
Rocker Arm Assembly: Testing and Inspection
Roller Follower Inspection
1. Inspect the roller follower for flat spots or scoring. If any damage is found, inspect the camshaft
lobes and hydraulic lash adjuster for damage.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Testing and Inspection > Page 2123
Rocker Arm Assembly: Service and Repair
Camshaft Roller Follower
Valve Train Components - Exploded View (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Testing and Inspection > Page 2124
Valve Train Components - Exploded View (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Testing and Inspection > Page 2125
Removal
1. Depending on the roller follower being serviced, remove the LH or RH valve cover. 2. Rotate the
crankshaft until the piston for the valve being serviced is at the top of its stroke with the intake valve
and the exhaust valves closed.
3. CAUTION: If the components are to be reinstalled, they must be installed in their original
positions. Mark the components for
installation into their original locations. Failure to follow these instructions may result in engine
damage.
NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder.
If a valve drops into the cylinder, the cylinder head must be removed.
NOTE: It may be necessary to push the valve down while compressing the spring.
Using the special tool, compress the valve spring and remove the camshaft roller follower.
4. Repeat the previous 2 steps for each roller follower being serviced. 5. Inspect the roller follower.
Installation
1. CAUTION: If the components are to be reinstalled, they must be installed in their original
positions. Mark the components for
installation into their original locations. Failure to follow these instructions may result in engine
damage.
NOTE: Lubricate the roller follower with clean engine oil.
Using the special tool, compress the valve spring and install the camshaft roller follower.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Testing and Inspection > Page 2126
2. Repeat the previous step for each roller follower being serviced. 3. Depending on the valve
being serviced, install the LH or RH valve cover.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > Valve Cover - LH > Page 2131
Removal
1. Remove the LH ignition coils. 2. Remove the bolt and position the oil level indicator and tube
aside. 3. Disconnect the evaporative emissions (EVAP) tube from the intake manifold. 4.
Disconnect the PCV hose from the valve cover. 5. Remove the nut and position the cooling fan
wiring harness bracket aside. 6. Disconnect the 2 pin-type retainers from the valve cover. 7.
Disconnect the variable camshaft timing (VCT) solenoid electrical connector. 8. Detach the wiring
harness retainers from the valve cover studs. 9. Disconnect the EVAP canister purge valve
electrical connector.
10. Disconnect the EVAP canister-to-EVAP canister purge valve EVAP hose from the EVAP
canister purge valve. 11. Loosen the 10 bolts and remove the LH valve cover and gasket.
^ Discard the gasket.
Installation
1. 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 old sealant.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > Valve Cover - LH > Page 2132
Clean the gasket mating surfaces. ^
Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal
surface prep. Follow the directions on the packaging.
^ Clean the valve cover gasket groove in the valve cover with soap and water or a suitable solvent.
2. Install a new gasket on the LH valve cover.
3. NOTE: If the valve cover is not secured within 4 minutes, the sealant must be removed and the
sealing area cleaned with metal surface cleaner.
Failure to follow this procedure may cause future oil leakage.
Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the
cylinder head.
4. Position the LH valve cover with a new gasket and tighten the bolts in the sequence shown.
^ Tighten to 10 Nm (89 lb-in).
5. Connect the EVAP canister-to-EVAP canister purge valve EVAP hose to the EVAP canister
purge valve. 6. Connect the EVAP canister purge valve electrical connector. 7. Attach the wiring
harness retainers to the valve cover studs. 8. Connect the VCT solenoid electrical connector. 9.
Connect the 2 pin-type retainers to the valve cover.
10. Position the cooling fan wiring harness bracket and install the nut.
^ Tighten to 25 Nm (18 lb-ft).
11. Connect the PCV hose to the valve cover.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > Valve Cover - LH > Page 2133
12. Connect the EVAP tube to the intake manifold. 13. Position the oil level indicator tube and
install the bolt.
^ Tighten to 10 Nm (89 lb-in).
14. Install the LH ignition coils.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > Valve Cover - LH > Page 2134
Valve Cover: Service and Repair Valve Cover - RH
Valve Cover - RH
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > Valve Cover - LH > Page 2135
Removal
1. Remove the air cleaner (ACL) and the ACL outlet pipe. For additional information, refer to Fuel
Delivery and Air Induction.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > Valve Cover - LH > Page 2136
2. Remove the RH ignition coils. 3. Disconnect the engine wiring harness from the PCM.
^ Disconnect the 2 PCM electrical connectors.
^ Disconnect the in-line electrical connector.
^ Detach the wiring harness retainer from the PCM bracket and position the wiring harness aside.
4. Disconnect the RH variable camshaft timing (VCT) oil control solenoid electrical connector. 5.
Detach the 2 wiring harness retainers from the RH valve cover studs. 6. Detach the wiring harness
pin-type retainer from the front of the RH valve cover. 7. Detach the heater hose retainer from the
RH valve cover. 8. Disconnect the crankcase breather tube from the RH valve cover. 9. Loosen the
9 RH valve cover bolts and remove the RH valve cover and the RH valve cover gasket.
^ Discard the gasket.
Installation
1. 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 old sealant.
Clean the gasket mating surfaces. ^
Clean the valve cover mating surface of the RH cylinder head with silicone gasket remover and
metal surface prep. Follow the directions on the packaging.
^ Clean the RH valve cover gasket groove with soap and water or a suitable solvent.
2. Install a new gasket on the RH valve cover.
3. NOTE: If the RH valve cover is not secured within 4 minutes, the sealant must be removed and
the sealing area cleaned with metal surface
cleaner. Failure to follow this procedure may cause future oil leakage.
Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the RH
cylinder head.
4. Position the RH valve cover with a new gasket on the cylinder head and tighten the bolts in the
sequence shown.
^ Tighten to 10 Nm (89 lb-in).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > Valve Cover - LH > Page 2137
5. Connect the crankcase breather tube to the RH valve cover. 6. Attach the heater hose retainer to
the RH valve cover. 7. Attach the wiring harness pin-type retainer to the front of the RH valve
cover. 8. Attach the wiring harness retainers to the RH valve cover studs. 9. Connect the RH VCT
oil control solenoid electrical connector.
10. Connect the engine wiring harness to the PCM.
^ Position the wiring harness and attach the wiring harness pin-type retainer to the PCM bracket.
^ Connect the in-line electrical connector.
^ Connect the 2 PCM electrical connectors.
11. Install the RH ignition coils. 12. Install the air cleaner and the air cleaner outlet pipe.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component
Information > Service and Repair
Valve Guide: Service and Repair
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, install a new cylinder head assembly.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component
Information > Service and Repair
Valve Seat: Service and Repair
Valve Seat Inspection
Valve and Seat Refacing Measurements
NOTE: 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. Install a new cylinder head assembly if
abnormalities are found.
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.
Valve Seat Runout
1. Use a valve seat runout gauge to check valve seat runout.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component
Information > Service and Repair > Page 2144
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Procedures
Valve Spring: Procedures
Valve Spring Installed Length
1. Measure the installed length of each valve spring.
Valve Spring Free Length
1. Measure the free length of each valve spring.
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.
Valve Spring Strength
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Procedures > Page 2149
1. Use the special tool to check the valve spring for correct strength at the specified valve spring
length.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Procedures > Page 2150
Valve Spring: Removal and Replacement
Valve Springs
Valve Train Components - Exploded View (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Procedures > Page 2151
Valve Train Components - Exploded View (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Procedures > Page 2152
Removal
1. Depending on the valve spring being serviced, remove the LH or RH valve cover. 2. Remove the
spark plug. 3. Rotate the crankshaft until the piston for the valve spring being serviced is at the top
of its stroke with the intake valve and the exhaust valves
closed.
4. CAUTION: If the components are to be reinstalled, they must be installed in their original
positions. Mark the components for
installation into their original locations. Failure to follow these instructions may result in engine
damage.
NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder.
If a valve drops into the cylinder, the cylinder head must be removed.
NOTE: It may be necessary to push the valve down while compressing the spring.
Using the special tool, compress the valve spring and remove the camshaft roller follower.
5. Use compressed air in the cylinder to hold both valves in position.
^ Apply a minimum of 965 kPa (140 psi) of compressed air into the cylinder.
6. CAUTION: If the components are to be reinstalled, they must be installed in their original
positions. Mark the components for
installation into their original locations. Failure to follow these instructions may result in engine
damage.
NOTE: 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. If a valve drops into the cylinder, remove the cylinder head.
Using the special tool, compress the valve spring and remove the valve spring retainer keys.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Procedures > Page 2153
7. Remove the valve spring retainer and the valve spring. 8. Inspect the valve spring.
Installation
1. CAUTION: If the components are to be reinstalled, they must be installed in their original
positions. Mark the components for
installation into their original locations. Failure to follow these instructions may result in engine
damage.
Using the special tool, install the valve spring, the valve spring retainer and the valve spring
retainer keys.
2. Relieve the air pressure from the cylinder.
3. CAUTION: If the components are to be reinstalled, they must be installed in their original
positions. Mark the components for
installation into their original locations. Failure to follow these instructions may result in engine
damage.
NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder.
If a valve drops into the cylinder, the cylinder head must be removed.
NOTE: It may be necessary to push the valve down while compressing the spring.
NOTE: Lubricate the camshaft roller followers with clean engine oil prior to installation.
Using the special tool, compress the valve spring and install the camshaft roller follower.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Procedures > Page 2154
4. Install the spark plug. 5. Depending on the valve spring being serviced, install the LH or RH
valve cover.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Service and Repair > Valve Stem Diameter > Page 2160
Valve: Service and Repair Valve Stem to Valve Guide Clearance
Valve Stem to Valve Guide Clearance
NOTE: The 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 Guide Clearance Gauge on the valve stem and install a Dial Indicator Gauge with
Holding Fixture. Lower the valve until the clearance gauge contacts the upper surface of the valve
guide.
2. Move the clearance gauge toward the indicator and zero the indicator. Move the clearance
gauge away from the indicator and note the reading.
The reading will be DOUBLE the valve stem-to-valve guide clearance.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > Customer Interest: > 09-9-7 > May > 09 > Engine - FEAD
Idler Pulley Noise During Cold Start
Drive Belt: Customer Interest Engine - FEAD Idler Pulley Noise During Cold Start
TSB 09-9-7
05/18/09
COLD START FEAD HOOT - WHISTLE NOISE
FORD: 2007-2008 Mustang, Expedition, Explorer Sport Trac, Explorer, F-150, F-150
LINCOLN: 2007-2008 Mark LT, Navigator
MERCURY: 2007-2008 Mountaineer
This article supersedes TSB 8-4-2 to remove the production build date.
ISSUE Some 2007-2008 F-150, Mustang vehicles equipped with a 4.6L and 5.4L engine;
2007-2008 Mark LT, Expedition, Navigator vehicles equipped with a 5.4L engine; Explorer,
Mountaineer, Explorer Sport Trac vehicles with 4.6L engine may exhibit a front end accessory drive
(FEAD) related high-pitched metallic whistle/hoot noise after a cold soak in ambient temperatures
below 40 °F (4.4 °C). This noise may be caused by the grooved nylon FEAD idler pulley.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
FEAD IDLER PULLEY NOISE MAY BE MOST APPARENT AT OR NEAR COLD ENGINE IDLE
SPEEDS (APPROXIMATELY 1200 RPM). NOISE DURATION IS LESS THAN 10 MINUTES
AFTER STARTUP AND WILL BE ELIMINATED WITH FEAD BELT REMOVED.
1. Replace the nylon FEAD idler pulley, refer to Workshop Manual, 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
090907A 2007-2008 F-150/Mark LT 0.3 Hr.
4.6L/5.4L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do
Not Use With 8678A, 8620F)
090907A 2007-2008 0.4 Hr.
Expedition/Navigator: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine
Belt (Do Not Use With 8678A, 8620F)
090907A 2007-2008 0.4 Hr.
Explorer/Mountaineer/
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > Customer Interest: > 09-9-7 > May > 09 > Engine - FEAD
Idler Pulley Noise During Cold Start > Page 2170
Sport Trac 4.6L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt
(Do Not Use With 8678A, 8620F)
090907A 2007-2008 Mustang 4.6L: 0.3 Hr.
Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With
8678A, 8620F)
DEALER CODING
CONDITION
BASIC PART NO. CODE
6C348 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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: > 09-9-7 > May > 09 > Engine
- FEAD Idler Pulley Noise During Cold Start
Drive Belt: All Technical Service Bulletins Engine - FEAD Idler Pulley Noise During Cold Start
TSB 09-9-7
05/18/09
COLD START FEAD HOOT - WHISTLE NOISE
FORD: 2007-2008 Mustang, Expedition, Explorer Sport Trac, Explorer, F-150, F-150
LINCOLN: 2007-2008 Mark LT, Navigator
MERCURY: 2007-2008 Mountaineer
This article supersedes TSB 8-4-2 to remove the production build date.
ISSUE Some 2007-2008 F-150, Mustang vehicles equipped with a 4.6L and 5.4L engine;
2007-2008 Mark LT, Expedition, Navigator vehicles equipped with a 5.4L engine; Explorer,
Mountaineer, Explorer Sport Trac vehicles with 4.6L engine may exhibit a front end accessory drive
(FEAD) related high-pitched metallic whistle/hoot noise after a cold soak in ambient temperatures
below 40 °F (4.4 °C). This noise may be caused by the grooved nylon FEAD idler pulley.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
FEAD IDLER PULLEY NOISE MAY BE MOST APPARENT AT OR NEAR COLD ENGINE IDLE
SPEEDS (APPROXIMATELY 1200 RPM). NOISE DURATION IS LESS THAN 10 MINUTES
AFTER STARTUP AND WILL BE ELIMINATED WITH FEAD BELT REMOVED.
1. Replace the nylon FEAD idler pulley, refer to Workshop Manual, 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
090907A 2007-2008 F-150/Mark LT 0.3 Hr.
4.6L/5.4L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do
Not Use With 8678A, 8620F)
090907A 2007-2008 0.4 Hr.
Expedition/Navigator: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine
Belt (Do Not Use With 8678A, 8620F)
090907A 2007-2008 0.4 Hr.
Explorer/Mountaineer/
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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: > 09-9-7 > May > 09 > Engine
- FEAD Idler Pulley Noise During Cold Start > Page 2176
Sport Trac 4.6L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt
(Do Not Use With 8678A, 8620F)
090907A 2007-2008 Mustang 4.6L: 0.3 Hr.
Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With
8678A, 8620F)
DEALER CODING
CONDITION
BASIC PART NO. CODE
6C348 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 10-9-7 > May > 10
> Audio System - Unexpected CD Shuffle With Key Off
Entertainment System Control Module: All Technical Service Bulletins Audio System - Unexpected
CD Shuffle With Key Off
TSB 10-9-7
05/24/10
UNEXPECTED COMPACT DISC SHUFFLE OR CYCLING DURING NORMAL RADIO
OPERATION OR WITH THE KEY OFF - NON-NAVIGATION RADIOS ONLY
FORD: 2008-2010 Expedition, Explorer Sport Trac, Explorer
MERCURY: 2008-2010 Mountaineer
ISSUE Some 2008-2010 Expedition, Explorer, Explorer Sport Trac and Mountaineer vehicles
equipped with a non-navigation CD-6 Audio Control Module (ACM) may experience an unexpected
Compact Disc (CD) shuffle or cycling during start up, during normal ACM operation, or shutting off
the vehicle.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
This service procedure affects non-navigation radios only. If you attempt to run module
reprogramming on the 2008-2010 ACM and the service tool does not recognize the part numbers
of the ACM currently installed, this procedure does not apply.
Reprogram the ACM to the latest calibration using IDS release 66.05A and higher. This new
calibration is not included in the VCM 2010. Version A 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
100907A 2008-2010 Expedition, 0.3 Hr.
Explorer, Mountaineer, And Explorer Sport Trac: Reprogram The Audio Control Module (Do Not
Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > Page 2187
Drive Belt: Diagrams
Component Locations - 4.6L (3V)
Component Locations - 4.6L (3V) (Part 1)
Component Locations - 4.6L (3V) (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Inspection and Verification
CAUTION: 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. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
mechanical damage.
Visual Inspection Chart
Visual Inspection Chart
Belt Tensioner With Belt Length Indicator
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 2190
3. Check that the belt length indicator, if equipped, on the belt tensioner is in the acceptable belt
installation and wear range. If the indicator is in the
belt replacement range, either an incorrect belt is installed or the belt is worn beyond the service
limit. Install a new belt as necessary.
4. Eliminate all other non-belt related noises that could cause belt misdiagnosis, such as A/C
compressor engagement chirp, A/C slugging noise,
power steering cavitations at low temperatures, variable camshaft timing (VCT) tick or generator
whine.
5. If a concern is found, correct the condition before proceeding to the next step.
V-Ribbed Serpentine Drive Belt With Cracks Across Ribs
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 2191
6. Check the belt for cracks. Up to 15 cracks in a rib over a distance of 100 mm (4.0 in) can be
considered acceptable. If cracks exceed this standard,
install a new belt.
V-Ribbed Serpentine Belt With Piling
7. 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 Chunks of Rib Missing
8. There should be no chunks missing from the belt ribs. If the belt shows any evidence of this,
install a new accessory drive belt. 9. 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 (V8-4.6L (2008))
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 2192
Drive Belt: Symptom Related Diagnostic Procedures
Symptom Chart
Symptom Chart (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 2193
Symptom Chart (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 2194
Drive Belt: Component Tests and General Diagnostics
Component Tests
Drive Belt - Noise/Flutter
CAUTION: 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.
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.
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 (WOT) 1-2 and 2-3 shifts or 2-3 and 3-4 back out shifts on automatic
transmissions.
^ WOT 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 or idler pulley(s) 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
CAUTION: Incorrect accessory drive belt installation will cause excessive drive belt wear and may
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 2195
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 and wear, especially the mounting
pad surface and arm alignment. If the accessory drive belt tensioner is not installed correctly, the
mounting surface pad will be out of position. If the tensioner arm is worn, the arm will be out of
alignment. Either of these conditions 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
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.
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 from the tensioner. Carry out the following tests: ^
Using the 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.
^ Rotate the tensioner pulley by hand and check for a binding, contaminated or seized condition.
^ Inspect the area surrounding the accessory drive belt tensioner for oil leaks or contamination and
repair any leaks.
3. If the accessory drive belt tensioner does not meet the criteria in the previous step, install a new
tensioner. If the accessory drive belt tensioner
meets the criteria in the previous step, proceed to testing the tensioner dynamically.
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
A/C clutch cycles (if equipped), or when the engine is accelerated rapidly. If the accessory drive
belt tensioner movement is excessive without A/C clutch cycling or engine acceleration, check belt
rideout. Excessive belt rideout (uneven depth of grooves in the belt) can cause excessive
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 2196
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 (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Testing and Inspection > Page 2197
Drive Belt: Service and Repair
Accessory Drive Belt - 4.6L (3V)
Front End Accessory Drive (FEAD) - Exploded View, 4.6L (3V)
Removal and Installation
1. Remove the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air
Induction. 2. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive
belt.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Testing and Inspection > Page 2198
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 - 4.6L (3V)
Front End Accessory Drive (FEAD) - Exploded View, 4.6L (3V)
Removal and Installation
1. Remove the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air
Induction. 2. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive
belt.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Service and Repair > Page 2202
3. Remove the bolts and the accessory drive belt tensioner.
^ To install, tighten to 25 Nm (18 lb-ft).
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Procedures
Engine Mount: Procedures
Powertrain/Drivetrain Mount Neutralizing
NOTE: Refer to the appropriate procedure for special instructions on loosening and tightening
mount fasteners.
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair. 2. Loosen, but do not remove, the powertrain/drivetrain mount
fasteners. 3. Lower the vehicle.
4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts or damage to the mounts may
occur.
Move the vehicle in forward and reverse 0.6-1.2 m (2-4 ft).
5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the
vehicle. 8. Test the system for normal operation.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Procedures > Page 2207
Engine Mount: Removal and Replacement
Engine Support Insulators
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Procedures > Page 2208
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Procedures > Page 2209
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 the engine cooling fan. For additional information,
refer to Cooling System. 3. Remove the throttle body (TB). For additional information, refer to Fuel
Delivery and Air Induction. 4. Remove the generator. For additional information, refer to Alternator.
5. Disconnect the PCV valve hose from the heated PCV fitting.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Procedures > Page 2210
6. Remove the bolts and position the heated PCV fitting aside. 7. Disconnect the evaporative
emission (EVAP) hose from the intake manifold. 8. Remove the 5 pushpins and the splash shield.
9. Remove the RH engine support insulator upper nuts.
^ To install, tighten to 90 Nm (66 lb-ft).
10. Remove the LH engine support insulator through bolt.
^ To install, tighten to 103 Nm (76 lb-ft).
11. Install the special tools and raise the engine approximately 70 mm (2.75 in).
RH side
12. Remove the RH engine support insulator lower nut.
^ To install, tighten to 90 Nm (66 lb-ft).
13. Remove the RH engine support insulator.
Four wheel drive (4WD) vehicles
14. Remove the stabilizer bar bracket bolts and allow the stabilizer bar to hang freely.
^ To install, tighten to 55 Nm (41 lb-ft).
15. WARNING: Secure the assembly to the jack. Avoid any obstructions while lowering and raising
the jack. Contact with obstructions may
cause the assembly to fall off the jack, which may result in serious personal injury.
Support the differential housing with a suitable jack stand.
16. Disconnect the vent hose from the differential housing vent tube.
17. CAUTION: Any time bolts, washers, spacers or nuts are loosened in the differential support for
any reason, install new components to
prevent damage.
Remove and discard the 3 bolts and 3 flagnuts. ^
To install, tighten to 66 Nm (49 lb-ft).
18. Lower the differential housing approximately 25 mm (1 in).
LH side
19. Remove the LH engine support insulator nut.
^ To install, tighten to 90 Nm (66 lb-ft).
20. Remove the engine support insulator. 21. To install, reverse the removal procedure.
^ If equipped, install new differential housing bolts and flagnuts.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Technical Service Bulletins > Customer Interest for Idler Pulley: > 09-9-7 > May > 09 >
Engine - FEAD Idler Pulley Noise During Cold Start
Idler Pulley: Customer Interest Engine - FEAD Idler Pulley Noise During Cold Start
TSB 09-9-7
05/18/09
COLD START FEAD HOOT - WHISTLE NOISE
FORD: 2007-2008 Mustang, Expedition, Explorer Sport Trac, Explorer, F-150, F-150
LINCOLN: 2007-2008 Mark LT, Navigator
MERCURY: 2007-2008 Mountaineer
This article supersedes TSB 8-4-2 to remove the production build date.
ISSUE Some 2007-2008 F-150, Mustang vehicles equipped with a 4.6L and 5.4L engine;
2007-2008 Mark LT, Expedition, Navigator vehicles equipped with a 5.4L engine; Explorer,
Mountaineer, Explorer Sport Trac vehicles with 4.6L engine may exhibit a front end accessory drive
(FEAD) related high-pitched metallic whistle/hoot noise after a cold soak in ambient temperatures
below 40 °F (4.4 °C). This noise may be caused by the grooved nylon FEAD idler pulley.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
FEAD IDLER PULLEY NOISE MAY BE MOST APPARENT AT OR NEAR COLD ENGINE IDLE
SPEEDS (APPROXIMATELY 1200 RPM). NOISE DURATION IS LESS THAN 10 MINUTES
AFTER STARTUP AND WILL BE ELIMINATED WITH FEAD BELT REMOVED.
1. Replace the nylon FEAD idler pulley, refer to Workshop Manual, 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
090907A 2007-2008 F-150/Mark LT 0.3 Hr.
4.6L/5.4L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do
Not Use With 8678A, 8620F)
090907A 2007-2008 0.4 Hr.
Expedition/Navigator: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine
Belt (Do Not Use With 8678A, 8620F)
090907A 2007-2008 0.4 Hr.
Explorer/Mountaineer/
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Technical Service Bulletins > Customer Interest for Idler Pulley: > 09-9-7 > May > 09 >
Engine - FEAD Idler Pulley Noise During Cold Start > Page 2219
Sport Trac 4.6L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt
(Do Not Use With 8678A, 8620F)
090907A 2007-2008 Mustang 4.6L: 0.3 Hr.
Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With
8678A, 8620F)
DEALER CODING
CONDITION
BASIC PART NO. CODE
6C348 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idler Pulley: > 09-9-7 >
May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start
Idler Pulley: All Technical Service Bulletins Engine - FEAD Idler Pulley Noise During Cold Start
TSB 09-9-7
05/18/09
COLD START FEAD HOOT - WHISTLE NOISE
FORD: 2007-2008 Mustang, Expedition, Explorer Sport Trac, Explorer, F-150, F-150
LINCOLN: 2007-2008 Mark LT, Navigator
MERCURY: 2007-2008 Mountaineer
This article supersedes TSB 8-4-2 to remove the production build date.
ISSUE Some 2007-2008 F-150, Mustang vehicles equipped with a 4.6L and 5.4L engine;
2007-2008 Mark LT, Expedition, Navigator vehicles equipped with a 5.4L engine; Explorer,
Mountaineer, Explorer Sport Trac vehicles with 4.6L engine may exhibit a front end accessory drive
(FEAD) related high-pitched metallic whistle/hoot noise after a cold soak in ambient temperatures
below 40 °F (4.4 °C). This noise may be caused by the grooved nylon FEAD idler pulley.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
FEAD IDLER PULLEY NOISE MAY BE MOST APPARENT AT OR NEAR COLD ENGINE IDLE
SPEEDS (APPROXIMATELY 1200 RPM). NOISE DURATION IS LESS THAN 10 MINUTES
AFTER STARTUP AND WILL BE ELIMINATED WITH FEAD BELT REMOVED.
1. Replace the nylon FEAD idler pulley, refer to Workshop Manual, 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
090907A 2007-2008 F-150/Mark LT 0.3 Hr.
4.6L/5.4L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do
Not Use With 8678A, 8620F)
090907A 2007-2008 0.4 Hr.
Expedition/Navigator: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine
Belt (Do Not Use With 8678A, 8620F)
090907A 2007-2008 0.4 Hr.
Explorer/Mountaineer/
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idler Pulley: > 09-9-7 >
May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start > Page 2225
Sport Trac 4.6L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt
(Do Not Use With 8678A, 8620F)
090907A 2007-2008 Mustang 4.6L: 0.3 Hr.
Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With
8678A, 8620F)
DEALER CODING
CONDITION
BASIC PART NO. CODE
6C348 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Technical Service Bulletins > Page 2226
Idler Pulley: Service and Repair
Accessory Drive Belt Idler Pulley - 4.6L (3V)
Front End Accessory Drive (FEAD) - Exploded View, 4.6L (3V)
Removal and Installation
1. Remove the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air
Induction. 2. Rotate the accessory drive belt tensioner clockwise and remove the drive belt.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Technical Service Bulletins > Page 2227
3. NOTE: The 4.6L (3V) has 3 idler pulleys, an upper RH, an upper LH and a lower LH.
Remove the bolt and the accessory drive belt idler pulley. ^
To install, tighten to 25 Nm (18 lb-ft).
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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)
.......................................................................................... 517 kPa (75 psi)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick
Tube > Component Information > Service and Repair
Engine Oil Dip Stick - Dip Stick Tube: Service and Repair
Oil Level Indicator and Tube
Removal and Installation
1. Remove the LH exhaust manifold. 2. Remove the oil level indicator and tube bolt.
^ To install, tighten to 10 Nm (89 lb-in).
3. Remove the oil level indicator and tube from the cylinder block. 4. Remove and discard the
O-ring seal.
5. NOTE: Install a new oil level indicator tube O-ring seal and lubricate it with clean engine oil prior
to installation.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Capacity Specifications
Engine Oil: Capacity Specifications
Engine Oil Capacity .............................................................................................................................
............................................................... 5.7L (6.0 qt)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Capacity Specifications > Page 2239
Engine Oil: Fluid Type Specifications
Engine Oil
U.S. .........................................................................................................................................
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil Canada
....................................................................................................................................................
Motorcraft SAE 5W-20 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-M2C930-A.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
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 engine cooling system. For additional information,
refer to Cooling System. 3. Drain the engine oil.
^ Install the drain plug and tighten to 23 Nm (17 lb-ft).
4. Disconnect the engine oil pressure switch electrical connector. 5. Disconnect the lower radiator
hose and position it aside. 6. Remove and discard the engine oil filter.
^ To install, lubricate the oil filter gasket with clean engine oil and tighten until the seal makes
contact.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component
Information > Service and Repair > Page 2243
- Using an oil filter strap wrench, tighten the filter an additional 270 degrees.
7. Remove the 4 bolts and the oil filter adapter.
^ To install, tighten to 25 Nm (18 lb-ft).
8. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These
may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing
surfaces.
Remove and discard the oil filter adapter gasket. ^
Clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the
directions on the packaging.
^ Inspect the mating surfaces.
9. To install, reverse the removal procedure.
^ Fill the engine with clean engine oil.
10. Fill and bleed the engine cooling system.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications
Oil Pan: Specifications
Oil Pan Bolts
First pass .............................................................................................................................................
..................................................... 2 Nm (18 lb-in). Second pass ........................................................
..................................................................................................................................... 20 Nm (15
lb-ft). Final pass ...................................................................................................................................
................................................ Tighten an additional 60°
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications > Page 2247
Oil Pan: Service and Repair
Oil Pan
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications > Page 2248
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications > Page 2249
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair. 2. Remove the front axle, if equipped. 3. Remove the stabilizer
bar. 4. Remove the drain plug and drain the engine oil. Install the drain plug when finished.
^ Tighten to 23 Nm (17 lb-ft).
5. Remove the nut and position the power steering pressure (PSP) hose bracket aside. 6. Remove
the nut and position the battery cable bracket aside. 7. Disconnect the oil temperature sensor
electrical connector. 8. Remove the bolts and the oil drain splash shield. 9. If equipped with a block
heater, detach the block heater wiring harness retainers from the LH side oil pan bolts.
10. Remove the bolts, the oil pan 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 the sealing surfaces. These
may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing
surfaces. Failure to follow these directions can cause future oil leaks.
Clean and inspect the sealing surfaces with silicone gasket remover, metal surface prep, and a
plastic scraper. Follow the directions on the packaging.
2. NOTE: If the oil pan and gasket are not secured within 4 minutes of sealer application, the
sealant must be removed and the sealing surfaces
cleaned with silicone gasket remover and metal surface prep. Follow the directions on the
packaging.
Apply silicone gasket and sealant in 2 places as shown.
3. NOTE: If the oil pan and gasket are not secured within 4 minutes of sealer application, the
sealant must be removed and the sealing surfaces
cleaned with silicone gasket remover and metal surface prep. Follow the directions on the
packaging.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications > Page 2250
Apply silicone gasket and sealant in 2 places as shown.
4. Position a new oil pan gasket and the oil pan and install the bolts finger-tight. 5. Tighten the bolt
in 3 stages in the sequence shown.
^ Stage 1: Tighten to 2 Nm (18 lb-in).
^ Stage 2: Tighten to 20 Nm (15 lb-ft).
^ Stage 3: Tighten an additional 60 degrees.
6. If equipped with a block heater, attach the block heater wiring harness retainers to the LH oil pan
bolts. 7. Position the oil drain splash shield and install the bolts.
^ Tighten to 12 Nm (9 lb-ft).
8. Connect the oil temperature sensor electrical connector. 9. Attach the battery cable bracket and
install the nut.
^ Tighten to 10 Nm (89 lb-in).
10. Attach the PSP hose bracket and install the nut.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications > Page 2251
^ Tighten to 10 Nm (89 lb-in).
11. Install the stabilizer bar. 12. Install the front axle, if equipped. 13. Fill the engine with clean
engine oil.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Locations
Oil Pressure Sender: Locations
View 151-1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Locations > Page 2255
View 151-9
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Locations > Page 2256
C103
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component
Information > Service and Repair > Page 2260
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component
Information > Service and Repair > Page 2261
Removal
1. Remove the oil pan. 2. Remove the bolts and the oil pump screen and pickup tube.
Installation
1. CAUTION: Make sure the O-ring seal is in place and not damaged. A missing or damaged
O-ring seal can cause foam in the lubrication
system, low oil pressure and severe engine damage.
NOTE: Clean and inspect the mating surfaces and install a new O-ring seal. Lubricate the O-ring
seal with clean engine oil prior to installation.
Position the oil pump screen and pickup tube and install the bolts. ^
Tighten the oil pump screen and pickup tube-to-oil pump bolts to 10 Nm (89 lb-in).
^ Tighten the oil pump screen and pickup tube-to-spacer bolt to 25 Nm (18 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component
Information > Service and Repair > Page 2262
2. Install the oil pan.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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)
.......................................................................................... 517 kPa (75 psi)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications
Intake Manifold: Specifications
Intake Manifold Bolts
First pass .............................................................................................................................................
..................................................... 2 Nm (18 lb-in). Final pass ............................................................
.................................................................................................................................... 10 Nm (89
lb-in).
Throttle Body Bolts ..............................................................................................................................
.................................................... 10 Nm (89 lb-in).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications > Page 2273
Intake Manifold: Service and Repair
Intake Manifold
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications > Page 2274
Removal
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working
on or near any fuel-related component. Highly flammable mixtures are always present and may be
ignited. Failure to follow these instructions may result in serious personal injury.
WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components,
relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system
remains under high pressure, even when the engine is not running. Failure to follow this instruction
may result in serious personal injury.
1. Release the fuel system pressure. For additional information, refer to Fuel Delivery and Air
Induction. 2. Remove the air cleaner outlet pipe. For additional information, refer to Fuel Delivery
and Air Induction. 3. Remove the fuel rail and injectors. For additional information, refer to Fuel
Delivery and Air Induction. 4. Disconnect the electronic throttle body (TB) electrical connector. 5.
Disconnect the evaporative emissions (EVAP) tube from the intake manifold. 6. Disconnect the
throttle position (TP) sensor electrical connector. 7. Disconnect the PCV hose from the heated PCV
fitting on the intake manifold. 8. Remove the bolts and position the heated PCV fitting aside.
^ Remove and discard the O-ring seal.
9. Detach the wiring harness retainers from the intake manifold.
10. Disconnect the charge motion control valve (CMCV) electrical connector. 11. Remove the bolts
and position the intake manifold forward. 12. Disconnect the brake booster vacuum hose from the
rear of the intake manifold. 13. Disconnect the vacuum hose from the rear of the intake manifold.
14. Remove the intake manifold and the gaskets.
^ Discard the gaskets.
Installation
1. 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 old gaskets.
NOTE: Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the
packaging.
NOTE: Electrical and vacuum harnesses must not restrict movement of the CMCV control rods at
the rear of the intake manifold. Use extreme care during the installation of the intake manifold to
prevent any pinching of electrical and vacuum harnesses.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications > Page 2275
Using new intake manifold gaskets, position the intake manifold.
2. Connect the vacuum hose to the rear of the intake manifold. 3. Connect the brake booster hose
to the rear of the intake manifold. 4. Install the intake manifold bolts and tighten the bolts in the
sequence shown in 2 stages.
^ Stage 1: Tighten to 2 Nm (18 lb-in).
^ Stage 2: Tighten to 10 Nm (89 lb-in).
5. Connect the CMCV electrical connector. 6. Attach the wiring harness retainers to the intake
manifold. 7. Install a new O-ring seal, position the heated PCV fitting and install the bolts. 8.
Connect the PCV hose to the heated PCV fitting on the intake manifold. 9. Connect the TP sensor
electrical connector.
10. Connect the EVAP hose to the intake manifold. 11. Connect the electronic TB electrical
connector. 12. Install the fuel rail and injectors. 13. Install the air cleaner outlet pipe.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair > Crankshaft Rear Seal
Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Seal
Crankshaft Rear Seal
Flexplate or Flywheel and Crankshaft Rear Seal - Exploded View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair > Crankshaft Rear Seal > Page 2281
Removal
1. Remove the flexplate. 2. Remove the engine-to-transmission spacer plate. 3. Using the special
tools, remove the crankshaft oil slinger.
^ Discard the crankshaft oil slinger.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair > Crankshaft Rear Seal > Page 2282
4. Using the special tools, remove the crankshaft rear seal.
^ Discard the crankshaft rear seal.
Installation
1. NOTE: Lubricate the inner lip of the crankshaft rear seal with clean engine oil.
Using the special tools, install the crankshaft rear seal.
2. Using the special tools, install the crankshaft rear oil slinger.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair > Crankshaft Rear Seal > Page 2283
3. Install the engine-to-transmission spacer plate. 4. Install the flexplate.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair > Crankshaft Rear Seal > Page 2284
Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Seal With Retainer Plate
Crankshaft Rear Seal with Retainer Plate
Flexplate or Flywheel and Crankshaft Rear Seal - Exploded View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair > Crankshaft Rear Seal > Page 2285
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair > Crankshaft Rear Seal > Page 2286
Removal
1. Remove the flexplate. 2. Remove the engine-to-transmission spacer plate. 3. Remove the oil
pan. 4. Using the special tools, remove the crankshaft oil slinger.
^ Discard the crankshaft oil slinger.
5. Using the special tools, remove the crankshaft rear seal.
^ Discard the crankshaft rear seal.
6. Remove the 6 bolts and the crankshaft rear seal retainer plate.
Installation
1. 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 old sealant.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair > Crankshaft Rear Seal > Page 2287
NOTE: Clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the
directions on the packaging. Failure to follow this procedure can cause future oil leakage.
Clean and inspect the mating surfaces.
2. NOTE: The crankshaft rear seal retaining plate does not have a sealant groove. Gasket maker
must be applied to the crankshaft rear seal retainer
plate mating surface on the engine block.
Apply a bead of gasket maker to the crankshaft rear seal retainer plate mating surface on the
engine block.
3. Install the crankshaft rear seal retainer plate and the 6 bolts in the sequence shown.
^ Tighten to 10 Nm (89 lb-in).
4. NOTE: Lubricate the inner lip of the crankshaft rear seal with clean engine oil.
Using the special tools, install the crankshaft rear seal.
5. Using the special tools, install the crankshaft rear oil slinger.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair > Crankshaft Rear Seal > Page 2288
6. Install the oil pan. 7. Install the engine-to-transmission spacer plate. 8. Install the flexplate.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Lower End Components - Exploded View, Crankshaft Pulley and Crankshaft Front Seal
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal >
Component Information > Service and Repair > Page 2292
Removal
1. Remove the crankshaft pulley. 2. Using the special tool, remove the crankshaft front seal.
Installation
1. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal >
Component Information > Service and Repair > Page 2293
2. Using the special tools, install the crankshaft front seal.
3. Install the crankshaft pulley.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Valve Train Components - Exploded View (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Page 2297
Valve Train Components - Exploded View (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Page 2298
Removal
1. Depending on the valve seal being serviced, remove the LH or RH valve cover. 2. Remove the
spark plug. 3. Rotate the crankshaft until the piston for the valve seal being serviced is at the top of
its stroke with the intake valve and the exhaust valves closed.
4. CAUTION: If the components are to be reinstalled, they must be installed in their original
positions. Mark the components for
installation into their original locations. Failure to follow these instructions may result in engine
damage.
NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder.
If a valve drops into the cylinder, the cylinder head must be removed.
NOTE: It may be necessary to push the valve down while compressing the spring.
Using the special tool, compress the valve spring and remove the camshaft roller follower.
5. Use compressed air in the cylinder to hold both valves in position.
^ Apply a minimum of 965 kPa (140 psi) of compressed air into the cylinder.
6. CAUTION: If the components are to be reinstalled, they must be installed in their original
positions. Mark the components for
installation into their original locations. Failure to follow these instructions may result in engine
damage.
NOTE: 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. If a valve drops into the cylinder, remove the cylinder head.
Using the special tool, compress the valve spring and remove the valve spring retainer keys.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Page 2299
7. Remove the valve spring retainer, the valve spring and the valve seal.
^ Discard the valve seal.
8. Inspect the components.
Installation
1. NOTE: Lubricate the valve seal and valve stem with clean engine oil prior to installation.
Position a new valve seal onto the valve stem.
2. Using the special tool, install the new valve seal.
3. CAUTION: If the components are to be reinstalled, they must be installed in their original
positions. Mark the components for
installation into their original locations. Failure to follow these instructions may result in engine
damage.
Using the special tool, install the valve spring, the valve spring retainer and the valve spring
retainer keys.
4. Relieve the air pressure from the cylinder.
5. CAUTION: If the components are to be reinstalled, they must be installed in their original
positions. Mark the components for
installation into their original locations. Failure to follow these instructions may result in engine
damage.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Page 2300
NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder.
If a valve drops into the cylinder, the cylinder head must be removed.
NOTE: It may be necessary to push the valve down while compressing the spring.
NOTE: Lubricate the camshaft roller followers with clean engine oil prior to installation.
Using the special tool, compress the valve spring and install the camshaft roller follower.
6. Install the spark plug. 7. Depending on the valve seal being serviced, install the LH or RH valve
cover.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender
> Component Information > Locations
Oil Pressure Sender: Locations
View 151-1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender
> Component Information > Locations > Page 2305
View 151-9
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender
> Component Information > Locations > Page 2306
C103
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket >
Component Information > Service and Repair
Camshaft Gear/Sprocket: Service and Repair
Camshaft Phaser and Sprocket
Valve Train Components - Exploded View (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket >
Component Information > Service and Repair > Page 2314
Valve Train Components - Exploded View (Part 2)
Removal
1. If servicing the RH camshaft phaser and sprocket, remove the RH camshaft. 2. If servicing the
LH camshaft phaser and sprocket, remove the LH camshaft.
3. CAUTION: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
NOTE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the special
tool is removed or out of placement, the engine front cover must be removed and the engine must
be retimed.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket >
Component Information > Service and Repair > Page 2315
Remove the camshaft phaser and sprocket from the timing chain.
4. Inspect the front of the camshaft phaser and sprocket for missing or damaged roll pins.
^ If the roll pins are missing or damaged, a new camshaft phaser and sprocket must be installed.
5. Inspect the rear of the camshaft phaser and sprocket for a deformed or damaged location pin.
^ If the location pin is deformed or damaged, a new camshaft phaser and sprocket must be
installed.
6. Visually inspect the camshaft phaser and sprocket for squareness (A). If the trigger wheel or
spring is deformed or damaged (B), install a new
camshaft phaser and sprocket.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket >
Component Information > Service and Repair > Page 2316
Installation
1. CAUTION: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
If installing a new camshaft phaser and sprocket, transfer the original scribe mark to the new
camshaft phaser and sprocket.
2. CAUTION: The timing chain must be installed in its original position onto the camshaft phaser
and sprocket using the scribed marks, or
damage to valves and pistons will result.
CAUTION: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
Align the scribe marks and position the camshaft phaser and sprocket into the timing chain.
3. If servicing the RH camshaft phaser and sprocket, install the RH camshaft. 4. If servicing the LH
camshaft phaser and sprocket, install the LH camshaft.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket >
Component Information > Specifications
Crankshaft Gear/Sprocket: Specifications
Crankshaft Pulley Bolt
Discard the crankshaft pulley bolt and washer.
First pass .............................................................................................................................................
.................................................... 90 Nm (66 lb-ft). Second pass ........................................................
............................................................................................................................................ Loosen
360° Third pass ...................................................................................................................................
............................................................ 50 Nm (37 lb-ft). Final pass ....................................................
............................................................................................................................... Tighten an
additional 90°
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Specifications
Timing Chain Tensioner: Specifications
Timing Chain Tensioner Bolts .............................................................................................................
.................................................... 25 Nm (18 lb.ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications
Timing Cover: Specifications
Engine Front Cover Front Fasteners
...................................................................................................................................................... 25
Nm (18 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2326
Engine Front Cover Lower Fasteners
First pass .............................................................................................................................................
.................................................... 20 Nm (15 lb-ft). Final pass ............................................................
....................................................................................................................... Tighten an additional
60°
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2327
Timing Cover: Service and Repair
Engine Front Cover
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2328
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2329
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2330
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 engine oil.
^ To install, tighten to 23 Nm (17 lb-ft).
3. Remove the cooling fan shroud. For additional information, refer to Cooling System. 4. Remove
the RH side idler pulley. For additional information, refer to Drive Belts, Mounts, Brackets and
Accessories. 5. Remove the RH valve cover. 6. Remove the LH valve cover. 7. Remove the nut
and position the RH radio interference capacitor aside. 8. Disconnect the RH camshaft position
(CMP) sensor electrical connector. 9. Remove the nut and the cooling fan wiring harness bracket.
10. Remove the nut and position the LH radio interference capacitor aside. 11. Disconnect the LH
CMP sensor electrical connector. 12. Remove the bolts and the coolant pump pulley. 13. Remove
the nuts and detach the battery cable bracket from the power steering pump stud bolts. 14. Detach
the wiring harness retainer from the power steering pump stud bolt. 15. Remove the stud bolts and
position the power steering pump aside.
^ Support the power steering pump with a length of mechanic's wire.
16. Remove the nut and detach the power steering pressure (PSP) hose bracket from the battery
cable bracket. 17. Remove the nut and detach the battery cable bracket from the engine front
cover. 18. Remove the nut and detach the transmission cooler tube bracket from the engine front
cover. 19. Disconnect the crankshaft position (CKP) sensor electrical connector. 20. Remove the
crankshaft pulley bolt and washer.
^ Discard the crankshaft pulley bolt.
21. Using the special tool, remove the crankshaft pulley.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2331
22. Using the special tool, remove the crankshaft front seal.
^ Discard the crankshaft front seal.
23. Remove the oil pan-to-engine front cover bolts. 24. Remove the engine front cover bolts and
stud bolts. 25. Remove the engine front cover from the engine front cover-to-cylinder block dowel.
^ Remove and discard the engine front cover gaskets.
Installation
1. 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 old sealant.
Clean the mating surfaces with silicone gasket remover, metal surface prep and a plastic scraping
tool. Follow the directions on the packaging.
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 old sealant.
NOTE: If the engine front cover is 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 a bead of silicone gasket and sealant along the cylinder head-to-cylinder block mating
surface and the oil pan-to-cylinder block mating
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2332
surface at the locations shown.
3. Install new engine front cover gaskets on the engine front cover. Position the engine front cover
onto the dowels. Install the fasteners finger tight.
4. Tighten the engine front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2333
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2334
5. Loosely install the oil pan-to-engine front cover bolts, then tighten the bolts in 2 stages in the
sequence shown.
^ Stage 1: Tighten to 20 Nm (15 lb-ft).
^ Stage 2: Tighten an additional 60 degrees.
6. Lubricate the engine front cover and a new crankshaft front seal inner lip with clean engine oil.
7. Using the special tools, install the crankshaft front seal.
8. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area
cleaned with 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 gasket sealant to the Woodruff key slot in the crankshaft pulley.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2335
9. Using the special tool, install the crankshaft pulley.
10. Using a new crankshaft pulley bolt, install the bolt and washer and tighten the bolt in 4 stages.
^ Stage 1: Tighten to 90 Nm (66 lb-ft).
^ Stage 2: Loosen 360 degrees.
^ Stage 3: Tighten to 50 Nm (37 lb-ft).
^ Stage 4: Tighten an additional 90 degrees.
11. Connect the CKP sensor electrical connector. 12. Attach the transmission cooler tube bracket
to the engine front cover and install the nut.
^ Tighten to 12 Nm (9 lb-ft).
13. Attach the battery cable bracket to the front cover and install the nut.
^ Tighten to 10 Nm (89 lb-in).
14. Attach the PSP hose bracket to the battery cable bracket and install the nut.
^ Tighten to 10 Nm (89 lb-in).
15. Position the power steering pump and install the stud bolts.
^ Tighten to 25 Nm (18 lb-ft).
16. Attach the wiring harness retainer to the power steering pump stud bolt. 17. Position the battery
cable bracket on the power steering pump stud bolts and install the nuts.
^ Tighten to 10 Nm (89 lb-in).
18. Position the coolant pump pulley and install the bolts.
^ Tighten the bolts to 25 Nm (18 lb-ft).
19. Connect the LH CMP sensor electrical connector. 20. Position the LH radio interference
capacitor and install the nut.
^ Tighten to 25 Nm (18 lb-ft).
21. Position the cooling fan wiring harness bracket and install the nut. 22. Connect the RH CMP
sensor electrical connector. 23. Position the RH radio interference capacitor and install the nut.
^ Tighten to 25 Nm (18 lb-ft).
24. Install the LH valve cover. 25. Install the RH valve cover. 26. Install the RH side idler pulley. 27.
Install the cooling fan shroud. 28. Fill the engine with clean engine oil.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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
2341
C1452
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Diagrams > Page 2342
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 (CKP) sensor 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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Diagrams > Page 2343
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.
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 (V8-4.6L (2008))
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 variable camshaft timing (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 (V8-4.6L (2008))
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 (KOEO)..............................................................................................................
.............................................207-276 kPa (30-40 psi) Engine running.................................................
..................................................................................................................................207-276 kPa
(30-40 psi)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Specifications > Page 2351
Fuel Pressure: Testing and Inspection
FUEL SYSTEM PRESSURE TEST
Special Tool(s)
Special Tool(s)
WARNING:
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious personal injury.
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the
fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under
high pressure, even when the engine is not running. Failure to follow this instruction may result in
serious 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 component. Highly flammable mixtures are always
present and may be ignited. Failure to follow these instructions may result in serious personal
injury.
- When handling fuel, always observe fuel handling precautions and be prepared in the event of
fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources.
Failure to follow these instructions may result in serious personal injury.
1. Disconnect the fuel supply tube-to-fuel rail spring lock coupling.
2. NOTE: 4.6L shown, 4.0L similar.
Install the special tool in line between the fuel supply tube and fuel rail.
3. NOTE: The inertia fuel shutoff (IFS) switch electrical connector was disconnected during fuel
system pressure release.
Connect the IFS switch electrical connector.
4. 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.
5. Test the fuel system pressure to make sure it is within the specified range.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Specifications > Page 2352
6. NOTE:
- 4.6L shown, 4.0L similar.
- Open the drain valve slowly to relieve the fuel system pressure. This may drain fuel from the
system. Place the fuel in a suitable container.
Upon completion of the fuel system pressure test, open the drain valve on the special tool and
relieve the fuel system pressure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Specifications
Idle Speed: Specifications
Typical Diagnostic Reference Value
Measured/PID Values 630 - 850 RPM ................................................................................................
...................................................................................................... Hot Idle
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Coolant Expansion Tank
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 2360
Intake Air System Components (4.0L SOHC)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 2361
Intake Air System Components - 4.6L (3V)
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 (ACL) outlet pipe.
Vehicles equipped with a 4.6L (3V) engine
2. Detach the wiring harness retainer from the coolant expansion tank.
All vehicles
3. Loosen the clamp and disconnect the ACL outlet pipe from the ACL. 4. Unclip and remove the
ACL cover. 5. Remove the ACL.
6. NOTE: Clean the inside of the ACL tray.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious personal injury.
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the
fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under
high pressure, even when the engine is not running. Failure to follow this instruction may result in
serious 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 (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing
Order > Component Information > Specifications
Firing Order: Specifications
Firing order...........................................................................................................................................
...........................................................1-3-7-2-6-5-4-8
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 before top dead center (BTDC)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Ignition Components RH Side
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Service and Repair > Page 2375
Ignition Components LH Side
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions
Spark Plug: Technical Service Bulletins Ignition System - Spark Plug Removal Instructions
TSB 08-7-6
04/14/08
SPARK PLUG REMOVAL INSTRUCTIONS - 4.6L 3V/5.4L 3V16.8L 3V
FORD: 2005-2008 Mustang 2004-2008 F-150 2005-2008 Expedition, F-Super Duty 2006-2008
Explorer, F-53 Motorhome Chassis 2007-2008 Explorer Sport Trac
LINCOLN: 2005-2008 Navigator 2006-2008 Mark LT
MERCURY: 2006-2008 Mountaineer
This article supersedes TSB 08-1-9 to update Vehicle Applications, Service Procedure and Part
List.
ISSUE Some 2004-2008 F-150, 2006-2008 Mark LT, 2005-2008 F-Super Duty, Expedition, and
Navigator, with 5.4L 3-V engine; 2005-2008 Mustang, 2006-2008 Explorer, Mountaineer, and
2007-2008 Explorer Sport Trac with 4.6L 3-V engine; 2005-2008 F-Super Duty, 2006-2008 and
F-Stripped Chassis, with 6.8L 3-V engine may experience difficulty with spark plug removal. This
may cause damage to the spark plug and leave part of the spark plug in the cylinder head. Affected
engine build dates are as follows: 5.4L 3-V and 6.8L 3-V before 10/9/07, 4.6L 3-V before 11/30/07.
ACTION Refer to the following Service Procedure for techniques to remove the spark plugs and
extract broken spark plugs.
SERVICE PROCEDURE
The engine build date can be read on the left hand cam cover information sticker.
To remove spark plugs without damage, it is necessary to adhere exactly to this procedure before
removal is attempted.
CAUTION
DO NOT REMOVE PLUGS WHEN THE ENGINE IS WARM OR HOT. THE ENGINE MUST BE AT
ROOM TEMPERATURE WHEN PERFORMING SPARK PLUG SERVICE. REMOVING THE
SPARK PLUGS FROM A WARM/HOT ENGINE INCREASES THE CHANCE THE THREADS
COULD BE DAMAGED.
Spark Plug Removal Procedure
1. Remove the coil-on-plug assemblies and thoroughly blow out the spark plug wells and
surrounding valve cover area with compressed air.
2. Back out the spark plugs no more than 1/8 to 1/4 of a turn. Using Motorcraft(R) Carburetor
Tune-Up Cleaner, fill the spark plug well just above where the jamb nut hex sits (1/2 - 3/4
teaspoon). A minimum period of 15 minutes of soak time is required. The cleaner will wick down to
the ground electrode shield and soften the carbon deposits in this time. DO NOT WORK the spark
plug back and forth at this point.
NOTE
COMPLETELY REVIEW THE PRODUCT LABEL FOR THE MOTORCRAFT CARBURETOR
TUNE-UP CLEANER PRODUCT - USE AT ROOM TEMPERATURE AND SHAKE WELL.
CAUTION
EXCESSIVE MOTORCRAFT(R) CARBURETOR TUNE-UP CLEANER, OR REPEATING THE
PROCESS SEVERAL TIMES WITH TOO MUCH CLEANER FLUID, COULD INTRODUCE
ENOUGH LIQUID VOLUME TO HYDRO-LOCK THE ENGINE.
CAUTION
DO NOT USE AIR OR POWER TOOLS FOR SPARK PLUG REMOVAL. SPARK PLUGS MUST
ONLY BE REMOVED WITH HAND TOOLS.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page
2380
3. Tighten, and then loosen the spark plug, working the plug back and forth. Some screeching and
high effort may be noticed. The expected removal torque is about 33 lb-ft (45 N.m). Repeat the
back and forth turning as needed until turning effort is reduced, and remove the spark plugs.
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP. (Figure 1)
Separated/Broken Spark Plug Removal
If the spark plug separates after following the Spark Plug Removal Procedure, it will fail in one of
three modes. Refer to the appropriate removal procedure as required.
a. Mode 1: The ground electrode shield is left behind as an empty shell. (Figure 2)
b. Mode 2: The entire porcelain insulator and ground electrode shield remains in the cylinder head.
(Figure 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page
2381
c. Mode 3: The upper section of porcelain broke off with remaining porcelain left inside the ground
shield. (Figure 4)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page
2382
Flowchart of procedure. (Figure 5)
Mode 1 Procedure:
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page
2383
Use Rotunda special service tool 303-1203 to remove an empty ground electrode shield from the
cylinder head. (Figure 6)
NOTE
THIS TOOL IS ONLY DESIGNED TO WORK WITH AN EMPTY GROUND ELECTRODE SHIELD.
IF PORCELAIN REMAINS, PROCEED TO MODE 2 OR 3 REMOVAL.
1. Modify vacuum cap to a 3/8" (10 mm) length for each ground electrode shield that needs to be
removed. (Figure 7)
2. Use the installation rod (J) provided with service tool 303-1203 update to install the modified
vacuum cap. Push the cap into the ground shield down to the electrode strap. This will plug and
protect the combustion chamber from contamination. (Figure 7)
3. Thread-tap the ground electrode shield using a 9.0 x 1.0 mm plug tap (tap profile is about 3-4
reduced diameter threads on the tip end).
a. Coat the end of the tap with general purpose grease. (Figure 8)
b. Turn the tap about 3 to 4 turns into the ground electrode shield. Back the tap up frequently to
break chips and avoid cut material from coiling-up in the spark plug well. A tap socket adaptor (K)
is provided with service tool 303-1203 update to connect the tap to a 3/8" socket
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page
2384
drive.
CAUTION
DO NOT ATTEMPT TO REMOVE THE GROUND ELECTRODE SHIELD WITH THE TAP AND
WRENCH. THE TAP MAY BREAK IF THIS IS ATTEMPTED.
4. Thread Rotunda special service tool 303-1203 into the ground electrode shield. (Figure 9)
a. Install the stepped end of the tool pilot bushing into the spark plug well ensuring it bottoms out.
b. Screw the center shank into the ground electrode shield. Do not over tighten the shank, to
prevent thread stripping.
c. Install the nylon washer and jack nut until finger tight.
d. Turn the jack nut until the ground electrode is freed from the cavity and withdraw the tool
assembly.
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP.
Mode 2 Procedure:
1. Add an additional 1/2 teaspoon Motorcraft® Carburetor Tune-Up Cleaner fluid into spark plug
well and allow 15 minutes of soak time.
2. Using long-reach nose pliers grasp and remove the porcelain with an up and down motion taking
care not to fracture the porcelain.
3. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder
head.
Mode 3 Procedure:
CAUTION
DO NOT DRIVE PORCELAIN DOWN INTO THE GROUND SHIELD WITH A PUNCH AS
FRAGMENTS MAY ENTER THE COMBUSTION CHAMBER.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page
2385
Use Rotunda special service tool kit 303-1398 to remove porcelain broken inside the ground
electrode shield. (FIGURE 10)
Porcelain Removal - Preparation
CAUTION
THE ENGINE AND THE BONDING ADHESIVE MUST BE ROOM TEMPERATURE OF 70 °F (21
°C) OR HIGHER FOR PROPER CURE AND BOND STRENGTH. VERIFY EXPIRATION DATE OF
ADHESIVE.
CAUTION
DO NOT REUSE PINS. THIS ENSURES THE CORRECT SURFACE CHARACTERISTICS FOR
BONDING.
1. Remove any remaining electrode material from broken porcelain with long nose reach pliers.
2. Spray Motorcraft® Metal Brake Parts Cleaner into the porcelain hole for 2-4 seconds using the
straw nozzle supplied with the brake cleaner can.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page
2386
3. Insert a pin (A) into the collet (B). Screw the collet onto the threaded rod (C). Install the
assembled collet, pin, and threaded rod into the steel tool pilot (F). (Figures 11 and 12)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page
2387
4. Retract the collet and pin into the steel tool pilot, protecting the pin. (Figures 13 and 14)
NOTE
PIN TIP DAMAGE OR BENT PINS WILL PREVENT INSERTION INTO THE PORCELAIN.
5. Insert the completed assembly into the spark plug well and fully engage the pin into the
porcelain. (Figure 15)
6. Spray Motorcraft(R) Metal Brake Parts Cleaner 2-4 seconds between the spark plug well and
steel tool pilot. The steel tool pilot must be lifted up approximately 1/2" to allow brake cleaner to
flood the porcelain and pin.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page
2388
7. Scrub the porcelain inside diameter by moving the threaded rod up and down vigorously. Take
care making sure the pin does not disengage the porcelain. (Figure 16).
8. Repeat Steps 6 and 7.
9. Remove the tool assembly. Again flood the porcelain with Motorcraft(R) Metal Brake Parts
Cleaner for 2-4 seconds, then blow out the entire spark plug well and porcelain with dry
compressed air.
NOTE
CLEAN AND DRY COMPONENTS ARE KEY TO BONDING THE PIN TO THE PORCELAIN.
10. Repeat Steps 1-9 to prepare remaining porcelain fragments as needed.
11. Disassemble the collet and pin from the threaded rod. Dry the tools thoroughly with dry
compressed air.
Porcelain Removal - Bonding Process
CAUTION
USE CARE TO PREVENT BONDING AGENT FROM CONTACTING THREADS IN CYLINDER
HEAD.
NOTE
WORKING TIME LIMIT OF LOCTITE(R) 638(TM) RETAINING COMPOUND IS 5 MINUTES.
1. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to opposite sides of a clean and dry
applicator (H). Excessive amounts of Loctite(R) 638(TM) are being used if it drips off the applicator.
(Figure 17)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page
2389
2. Insert applicator into the porcelain and move applicator up and down 1/2" (13 mm) while turning
to spread the Loctite® 638TM on the inside of the porcelain. (Figure 18).
3. Add additional Loctite(R) 638(TM), repeating Steps 1 and 2.
4. Clean the applicator with Motorcraft(R) Metal Brake Parts Cleaner before the bonding agent
starts to cure.
5. Reassemble a dry and clean collet and pin assembly.
6. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to the pin. Excessive amounts of
Loctite® 638TMare being used if it drips off the pin.
7. Retract the collet and pin into the steel tool pilot to protect the Loctite(R) 638(TM) coated pin.
8. Insert the completed assembly into spark plug well and fully engage the pin into the porcelain
with a twisting motion to spread the bonding agent.
9. Add additional Loctite® 638TM, repeating Steps 6-8.
10. Leave the pin fully inserted in the porcelain while the adhesive cures. Replace the steel tool
pilot with the aluminum alignment sleeve (G), Figure 9, to support the threaded rod while the
adhesive cures if additional porcelain fragments are present in other cylinders. (Figure 19).
CAUTION
A MINIMUM 1 HOUR CURING TIME AT 70 °F (21 °C) DEGREES IS REQUIRED BEFORE
EXTRACTION IS ATTEMPTED.
11. Allow the Loctite(R) 638(TM) to cure for a minimum of one hour at 70 °F (21 °C).
12. Repeat the bonding process for remaining cylinders as needed.
Porcelain Removal - Extraction
1. After a minimum of one hour curing at 70 °F (21 °C), install the steel pilot tool over the threaded
rod.
2. Install the washer and jack nut until finger tight against the tool pilot bushing.
CAUTION
ONLY THE STEEL PILOT TOOL IS ACCEPTABLE FOR USE IN PORCELAIN REMOVAL.
3. While holding the end of the threaded rod with a wrench, tighten the jack nut until the porcelain is
free of the ground electrode.
4. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder
head.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page
2390
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP. (FIGURE 7)
Porcelain Removal - Pin Slipped Out
In the unlikely event that the pin does not remove the broken porcelain, this process can be
repeated.
Key elements to success are:
^ Clean and dry porcelain
^ Sufficient Loctite® 638TM Retaining Compound spread uniformly
^ Loctite(R) 638(TM) cure time and temperature
^ Preventing the threaded rod from rotating while removing the porcelain
Replacement Supplies
Replacement kit components and additional kit consumables (Loctite(R) 638TM Retaining
Compound and pins) can be obtained by calling 1-800-ROTUNDA, Option 5.
Parts Block
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
MT080706 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
12405 01
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (not adjustable)............................................................................................................
...................................1.02-1.28 mm (0.040-0.050 in)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > General Specifications > Page 2393
Torque Specifications
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 2394
Spark Plug: Application and ID
Item.......................................................................................................................................................
..............................................................Specification
Spark plug type (early build - black coil boot).......................................................................................
....................................................................PZT-14F Spark plug type (late build - brown coil boot)....
....................................................................................................................................................HJFS
-24FP
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 2395
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.
^
Install new spark plugs.
4. Inspect for normal burning.
^ Check for light tan or gray deposits on the firing tip.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 2396
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(R) 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 a 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.
^ Install new spark plugs.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 2397
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 2398
Spark Plug: Service and Repair
Ignition Components RH Side
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 2399
Ignition Components LH Side
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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.
Compression Pressure Limit Chart (Part 1)
Compression Pressure Limit Chart (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications > Page 2403
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 (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications > Page 2404
Compression Pressure Limit Chart (Part 2)
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
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 (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve
Clearance > System Information > Specifications
Valve Clearance: Specifications
Valve Clearance
This engine is equipped with hydraulic lash adjusters. No adjustment is required.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications
Water Pump: Specifications
Coolant Pump Bolts .............................................................................................................................
..................................................... 25 Nm (18 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications
> Page 2411
Water Pump: Service and Repair
Coolant Pump - 4.6L (3V)
Removal and Installation
1. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling
and Bleeding. 2. Remove the cooling fan. 3. Remove the accessory drive belt. For additional
information, refer to Drive Belts, Mounts, Brackets and Accessories. 4. Remove the bolts and the
coolant pump pulley.
^ To install, tighten to 25 Nm (18 lb-ft).
5. Remove the bolts and the coolant pump.
^ To install, tighten to 25 Nm (18 lb-ft).
6. Remove and discard the coolant pump O-ring.
7. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications
> Page 2412
tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all
traces of the old O-ring.
Clean the mating surfaces with a plastic scraper, if necessary, and metal surface prep. Follow the
directions on the packaging.
8. To install, reverse the removal procedure.
^ Install a new coolant pump O-ring. Lubricate the O-ring with clean engine coolant.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Capacity Specifications
Coolant: Capacity Specifications
Coolant Capacity:
Without auxiliary climate control
............................................................................................................................................................
13.9 qts (13.2L)
With auxiliary climate control ...............................................................................................................
.................................................. 15.7 qts (14.9L)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Capacity Specifications > Page 2418
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 (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information >
Service and Repair > Page 2422
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information >
Service and Repair > Page 2423
Removal and Installation
1. Drain the engine cooling system. 2. Remove the intake manifold. 3. Rotate the accessory drive
belt tensioner clockwise and detach the belt from the generator pulley.
4. Disconnect the electrical connector. 5. Loosen the generator nuts.
^ To install, tighten to 25 Nm (18 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information >
Service and Repair > Page 2424
6. 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 lb-in).
7. Disconnect the PCV heater hose from the coolant crossover manifold assembly. 8. Disconnect
the heater hose from the coolant crossover manifold assembly. 9. Disconnect the upper radiator
hose from the coolant crossover manifold assembly.
10. Remove the bolts, the coolant crossover manifold assembly and the gaskets. Discard the
gaskets.
^ To install, tighten to 10 Nm (89 lb-in).
11. To install, reverse the removal procedure.
^ Install new gaskets.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information >
Service and Repair
Coolant Reservoir: Service and Repair
Coolant Expansion Tank
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 lb-in).
4. To install, reverse the removal procedure.
^ Fill the coolant expansion tank with a 50/50 mixture of coolant and clean, drinkable water.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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, Taurus/Taurus X/Sable, 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): PCM FC Output State For Cooling Fan Speeds
2.3L Escape: 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 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 (V8-4.6L (2008))
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 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 (V8-4.6L (2008))
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
Removal and Installation
Vehicle equipped with a 4.6L (3V)
1. Remove the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air
Induction.
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 lb-in).
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 lb-in).
5. Disconnect the fan clutch electrical connector. 6. Remove the fan clutch wiring harness bracket
bolt.
^ To install, tighten to 7 Nm (62 lb-in).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade >
Component Information > Service and Repair > Page 2438
7. CAUTION: Do not side load the cooling fan clutch coil or the cooling fan clutch coil may be
damaged.
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 lb-ft).
8. Remove the bolts and separate the fan from the fan clutch.
^ To install, tighten to 7 Nm (62 lb-in).
9. If necessary, unclip and disconnect the fan clutch wiring harness.
10. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch >
Component Information > Diagrams
C1158
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch >
Component Information > Diagrams > Page 2442
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 (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch >
Component Information > Diagrams > Page 2443
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 (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams
C1064
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Engine Temperature Sensor > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Engine Temperature Sensor > Component Information > Locations > Page 2451
C107
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Engine Temperature Sensor > Component Information > Locations > Page 2452
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 (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Engine Temperature Sensor > Component Information > Locations > Page 2453
Engine Temperature Sensor: Service and Repair
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Removal and Installation
1. Disconnect the battery ground cable. 2. Remove the intake manifold. 3. Disconnect the cylinder
head temperature (CHT) sensor electrical connector. 4. Remove and discard the CHT sensor.
- To install, tighten to 26 Nm 19 lb-ft).
5. To install, reverse the removal procedure.
- Do not reuse the CHT sensor. Install a new sensor.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information >
Service and Repair
Fan Shroud: Service and Repair
Cooling Fan Shroud
Removal and Installation
Vehicles equipped with a 4.6L (3V) engine
1. Remove the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air
Induction.
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 lb-in).
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 lb-in).
5. Disconnect the fan clutch electrical connector. 6. Remove the fan clutch wiring harness bracket
bolt.
^ To install, tighten to 7 Nm (62 lb-in).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information >
Service and Repair > Page 2457
7. CAUTION: Do not side load the cooling fan clutch coil or the cooling fan clutch coil may be
damaged.
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 lb-ft).
8. Remove the bolts and the lower fan shroud.
^ To install, tighten to 7 Nm (62 lb-in).
9. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Testing and Inspection
Heater Core: Testing and Inspection
HEATER CORE
1. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores were
good and did not require replacement. If a heater
core leak is suspected, the heater core must be tested by carrying out the plugged heater core
component test before the heater core pressure test. Carry out a system inspection by checking
the heater system thoroughly as follows:
Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A
coolant leak in the heater water hose could follow the heater core tube to the heater core and
appear as a leak in the heater core.
2. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of
non-specification clamps can cause leakage at
the heater water hose connection and damage the heater core.
Check the integrity of the heater water hose clamps.
Heater Core - Plugged
1. Check to see that the engine coolant is at the correct level. 2. Start the engine and turn on the
heater. 3. When the engine coolant reaches operating temperature, feel the heater core inlet and
outlet hose to see if they are hot.
If the inlet hose is not hot: the heater control valve may be stuck closed.
- the thermostat is not working correctly.
If the outlet hose is not hot: the heater core may have an air pocket.
- the heater core may be restricted or plugged.
Heater Core - Pressure Test
Use the Radiator/Heater Core Pressure Tester to perform the pressure test.
1. NOTE: Due to space limitations, a bench test may be necessary for pressure testing.
Clamp off the heater hoses.
2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater hose,
approximately 101 mm (4 in) long on each heater core tube. 4. Fill the heater core and heater
water hoses with water and install Plug BT-7422-B and Adapter BT-7422-A from the
Radiator/Heater Core
Pressure Tester in the heater water hose ends. Secure the heater water hoses, plug and adapter
with hose clamps.
5. Attach the pump and gauge assembly from the Radiator/Heater Core Pressure Tester to the
adapter. 6. Close the bleed valve at the base of the gauge. Pump 138 kPa (20 psi) of air pressure
into the heater core. 7. Observe the pressure gauge for a minimum of 3 minutes. 8. If the pressure
drops, check the heater water hose connections to the core tubes for leaks. If the heater water
hoses do not leak, remove the heater
core from the vehicle and perform the bench test.
Heater Core - Bench Test
1. Remove the heater core from the vehicle. 2. Drain all of the coolant from the heater core. 3.
Connect the 101 mm (4 in) test heater water hoses with plug and adapter to the core tubes. Then
connect the radiator/heater core pressure tester to
the adapter.
4. Apply 138 kPa (20 psi) of air pressure to the heater core. Submerge the heater core in water.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Testing and Inspection > Page 2464
5. If a leak is observed, replace the heater core.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Heater Core > Page 2467
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 (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Heater Core > Page 2468
Heater Core: Service and Repair Auxiliary Heater Core
AUXILIARY HEATER CORE
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Heater Core > Page 2469
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 (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Heater Core > Page 2470
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Auxiliary Heater Outlet and Inlet Line - Front > Page 2475
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Auxiliary Heater Outlet and Inlet Line - Front > Page 2476
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.
- 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 (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service
and Repair
Radiator: Service and Repair
Radiator
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service
and Repair > Page 2480
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service
and Repair > Page 2481
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service
and Repair > Page 2482
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service
and Repair > Page 2483
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service
and Repair > Page 2484
2. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling
and Bleeding.
Vehicles equipped with a 4.6L (3V) engine
3. Remove the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air
Induction.
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 lb-in).
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.
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 lb-in).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service
and Repair > Page 2485
14. Disconnect the fan clutch electrical connector. 15. Remove the fan clutch wiring harness
bracket bolt.
^ To install, tighten to 7 Nm (62 lb-in).
16. CAUTION: Do not side load the cooling fan clutch coil or the cooling fan clutch coil may be
damaged.
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 lb-ft).
17. Remove the bolts and the lower fan shroud. 18. Detach the A/C tube from the retainer on the
radiator support bracket. 19. Remove the radiator support bracket-to-radiator support bracket bolts.
^ To install, tighten to 15 Nm (11 lb-ft).
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 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service
and Repair > Page 2486
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 lb-ft).
24. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 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 (V8-4.6L (2008))
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 > Diagrams
C1064
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page
2498
C107
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page
2499
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 (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page
2500
Engine Temperature Sensor: Service and Repair
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Removal and Installation
1. Disconnect the battery ground cable. 2. Remove the intake manifold. 3. Disconnect the cylinder
head temperature (CHT) sensor electrical connector. 4. Remove and discard the CHT sensor.
- To install, tighten to 26 Nm 19 lb-ft).
5. To install, reverse the removal procedure.
- Do not reuse the CHT sensor. Install a new sensor.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Specifications
Thermostat: Specifications
Thermostat Opening Temperatures Starts to open .............................................................................
........................................................................................................ 87-91° C (189-196° F) Fully
open .....................................................................................................................................................
................................................ 100° C (212° F)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Specifications > Page 2504
Thermostat: Service and Repair
Thermostat - 4.6L (3V)
Removal and Installation
1. Drain the cooling system. 2. Remove the throttle body. For additional information, refer to Fuel
Delivery and Air Induction. 3. Disconnect the fuel vapor tube. 4. Remove the bolts and position the
thermostat housing cover aside. 5. Remove the O-ring seal and the thermostat.
Installation
1. Install the thermostat with the spring facing down.
2. NOTE: Inspect the thermostat housing cover O-ring seal. Install a new O-ring seal, if necessary.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Specifications > Page 2505
Install the O-ring seal.
3. Position the thermostat housing cover and the bolts.
^ Tighten to 10 Nm (89 lb-in).
4. Connect the fuel vapor hose. 5. Install the throttle body. 6. Fill and bleed the cooling system.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications
Water Pump: Specifications
Coolant Pump Bolts .............................................................................................................................
..................................................... 25 Nm (18 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications > Page 2509
Water Pump: Service and Repair
Coolant Pump - 4.6L (3V)
Removal and Installation
1. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling
and Bleeding. 2. Remove the cooling fan. 3. Remove the accessory drive belt. For additional
information, refer to Drive Belts, Mounts, Brackets and Accessories. 4. Remove the bolts and the
coolant pump pulley.
^ To install, tighten to 25 Nm (18 lb-ft).
5. Remove the bolts and the coolant pump.
^ To install, tighten to 25 Nm (18 lb-ft).
6. Remove and discard the coolant pump O-ring.
7. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications > Page 2510
tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all
traces of the old O-ring.
Clean the mating surfaces with a plastic scraper, if necessary, and metal surface prep. Follow the
directions on the packaging.
8. To install, reverse the removal procedure.
^ Install a new coolant pump O-ring. Lubricate the O-ring with clean engine coolant.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
powertrain control module (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/Catalyst Efficiency Monitor
For 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).
Catalytic Converter
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Page 2515
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 (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Page 2516
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 Exhaust System for the exhaust system-exploded view.
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 PCM with 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 (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component
Information > Service and Repair
Exhaust Crossover Pipe: Service and Repair
Exhaust Y-Pipe - Dual Catalytic Converter
Exhaust System - Exploded View 4.0L Explorer Sport Trac (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component
Information > Service and Repair > Page 2520
Exhaust System - Exploded View 4.0L Explorer Sport Trac (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component
Information > Service and Repair > Page 2521
Exhaust System - Exploded View 4.6L Explorer Sport Trac (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component
Information > Service and Repair > Page 2522
Exhaust System - Exploded View 4.6L Explorer Sport Trac (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component
Information > Service and Repair > Page 2523
Exhaust System - Exploded View 4.0L Explorer/Mountaineer (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component
Information > Service and Repair > Page 2524
Exhaust System - Exploded View 4.0L Explorer/Mountaineer (Part 2)
Exhaust System - Exploded View 4.6L Explorer/Mountaineer (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component
Information > Service and Repair > Page 2525
Exhaust System - Exploded View 4.6L Explorer/Mountaineer (Part 2)
Removal
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 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: RH side shown, LH similar.
NOTE: Install new exhaust Y-pipe dual catalytic converter-to-exhaust manifold nuts.
NOTE: Do not fully torque the exhaust Y-pipe dual catalytic converter-to-exhaust manifold joint.
Position the exhaust Y-pipe dual catalytic converter to the exhaust manifold and loosely tighten all
nuts to stiffen the joint enough to maintain position.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component
Information > Service and Repair > Page 2526
^ Tighten to 8 Nm (71 lb-in) and then add additional torque if needed to stiffen the joint.
2. NOTE: Install new exhaust Y-pipe dual catalytic converter-to-muffler assembly gasket and nuts.
Install the exhaust Y-pipe-dual catalytic converter-to-muffler assembly new gasket, bolts and new
nuts. ^
Tighten to 40 Nm (30 lb-ft).
3. NOTE: RH shown, LH similar.
Tighten the exhaust Y-pipe dual catalytic converter-to-exhaust manifold nuts. ^
Tighten to 40 Nm (30 lb-ft).
4. Install the transmission support crossmember. 5. Connect the HO2S and catalyst monitor
sensors electrical connectors. 6. Check to see if the exhaust system isolators are at zero load. If
the exhaust system isolators are not at zero load, then carry out the exhaust system
alignment procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Specifications
Exhaust Manifold: Specifications
Exhaust Manifold Studs .......................................................................................................................
...................................................... 12 Nm (9 lb-ft).
Discard the studs.
Exhaust Manifold Nuts .........................................................................................................................
.................................................... 25 Nm (18 lb-ft).
Discard the nuts.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Specifications > Page 2530
Exhaust Manifold: Testing and Inspection
Exhaust Manifold Cleaning and Inspection
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.
NOTE: Use a straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002
in) per running foot of length, such as Snap-On(R) GA438A or equivalent. For example, if the
straightedge is 61 cm (24 in) long, the machined edge must be flat within 0.010 mm (0.0004 in)
from end to end.
Using the 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 in), install a new exhaust manifold.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Removal
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Service and Repair > Exhaust Manifold - LH > Page 2533
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair. 2. Detach the evaporative emission (EVAP) canister purge valve
from the bracket and position the valve aside.
3. CAUTION: Do not allow the lower steering column shaft to rotate while it is disconnected from
the gear or the clockspring may be
damaged. If there is evidence that the lower steering column shaft has rotated, the clockspring
must be removed and recentered. For additional information, refer to Air Bag Systems.
Remove the intermediate steering shaft pinch bolt and disconnect the intermediate steering shaft
from the lower steering column shaft.
4. Remove the 4 nuts and disconnect the dual converter Y-pipe from the exhaust manifolds. 5.
Remove the nuts and position the battery cable bracket aside. 6. Remove the bolts and the LH
exhaust manifold heat shield. 7. Remove and discard the pushpin. 8. Remove the 8 nuts, the LH
exhaust manifold and the gaskets.
^ Deflect the inner fender splash shield and remove the manifold between the splash shield and the
frame rail.
^ Discard the nuts and the gaskets.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Service and Repair > Exhaust Manifold - LH > Page 2534
9. Remove and discard the 8 LH exhaust manifold studs.
Installation
1. Inspect the LH exhaust manifold gasket mating surfaces for flatness. 2. Install 8 new LH exhaust
manifold studs.
^ Tighten to 12 Nm (9 lb-ft).
3. Position the new gaskets, the LH exhaust manifold and install new nuts finger-tight.
^ Deflect the inner fender splash shield and install the exhaust manifold between the splash shield
and the frame rail.
4. Tighten the exhaust manifold nuts in the sequence shown.
^ Tighten to 25 Nm (18 lb-ft).
5. Position the inner fender splash shield and install a new pushpin. 6. Install the heat shield and
the bolts.
^ Tighten to 10 Nm (89 lb-in).
7. Position the battery cable bracket and install the nuts.
^ Tighten to 10 Nm (89 lb-in).
8. Connect the dual converter Y-pipe to the exhaust manifolds and install the 4 nuts.
^ Tighten to 40 Nm (30 lb-ft).
9. Connect the intermediate steering shaft to the lower steering column shaft and install the pinch
bolt.
^ Tighten to 48 Nm (35 lb-ft).
10. Attach the EVAP canister purge valve to the bracket.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Service and Repair > Exhaust Manifold - LH > Page 2535
Exhaust Manifold: Service and Repair Exhaust Manifold - RH
Exhaust Manifold - RH
Removal
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Service and Repair > Exhaust Manifold - LH > Page 2536
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair. 2. Remove the 4 nuts and disconnect the dual converter Y-pipe
from the exhaust manifolds. 3. Remove the bolts and the RH exhaust manifold heat shield. 4.
Remove the pushpins and the RH splash shield. 5. Remove the 8 nuts, the RH exhaust manifold
and the gaskets.
^ Discard the nuts and the gaskets.
6. Remove and discard the 8 RH exhaust manifold studs.
Installation
1. Inspect the exhaust manifold gasket mating surfaces for flatness. 2. Install 8 new RH exhaust
manifold studs.
^ Tighten to 12 Nm (9 lb-ft).
3. Position the new gaskets, the RH exhaust manifold and install new nuts finger-tight. 4. Tighten
the nuts in the sequence shown.
^ Tighten to 25 Nm (18 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Service and Repair > Exhaust Manifold - LH > Page 2537
5. Position the RH splash shield and install the pushpins. 6. Position the heat shield and install the
bolts.
^ Tighten to 10 Nm (89 lb-in).
7. Connect the dual converter Y-pipe to the exhaust manifolds and install the nuts.
^ Tighten to 40 Nm (30 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information >
Service and Repair
Exhaust Pipe: Service and Repair
Tailpipe
Exhaust System - Exploded View 4.0L Explorer Sport Trac (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information >
Service and Repair > Page 2541
Exhaust System - Exploded View 4.0L Explorer Sport Trac (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information >
Service and Repair > Page 2542
Exhaust System - Exploded View 4.6L Explorer Sport Trac (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information >
Service and Repair > Page 2543
Exhaust System - Exploded View 4.6L Explorer Sport Trac (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information >
Service and Repair > Page 2544
Exhaust System - Exploded View 4.0L Explorer/Mountaineer (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information >
Service and Repair > Page 2545
Exhaust System - Exploded View 4.0L Explorer/Mountaineer (Part 2)
Exhaust System - Exploded View 4.6L Explorer/Mountaineer (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information >
Service and Repair > Page 2546
Exhaust System - Exploded View 4.6L Explorer/Mountaineer (Part 2)
Removal
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. Loosen the muffler assembly-to-tailpipe Torca(R) clamp. 3.
Disconnect the rubber isolator and remove the tailpipe.
Installation
1. Position the tailpipe and connect the rubber isolator.
2. NOTE: Using an abrasive pad, clean the muffler assembly-to-tailpipe surface area of any rust.
Position the muffler assembly-to-tailpipe and make sure the tab on the muffler assembly is seated
inside the notch on the tailpipe and then tighten the Torca(R) clamp. ^
Tighten to 48 Nm (35 lb-ft).
3. Check to see if the exhaust system isolators are at zero load. If the exhaust system isolators are
not at zero load, then carry out the exhaust system
alignment procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service
and Repair
Muffler: Service and Repair
Muffler
Exhaust System - Exploded View 4.0L Explorer Sport Trac (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service
and Repair > Page 2550
Exhaust System - Exploded View 4.0L Explorer Sport Trac (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service
and Repair > Page 2551
Exhaust System - Exploded View 4.6L Explorer Sport Trac (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service
and Repair > Page 2552
Exhaust System - Exploded View 4.6L Explorer Sport Trac (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service
and Repair > Page 2553
Exhaust System - Exploded View 4.0L Explorer/Mountaineer (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service
and Repair > Page 2554
Exhaust System - Exploded View 4.0L Explorer/Mountaineer (Part 2)
Exhaust System - Exploded View 4.6L Explorer/Mountaineer (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service
and Repair > Page 2555
Exhaust System - Exploded View 4.6L Explorer/Mountaineer (Part 2)
Removal
All vehicles
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.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service
and Repair > Page 2556
All vehicles
5. 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 nuts and gasket.
7. Disconnect the rubber isolators and remove the muffler assembly.
Installation
All vehicles
1. Position the muffler assembly and connect the rubber isolators.
2. NOTE: Using an abrasive pad, clean the muffler assembly-to-tailpipe surface area of any rust.
Position the muffler assembly-to-tailpipe and make sure the tab on the muffler assembly is seated
inside the notch on the tailpipe and then tighten the Torca(R) clamp. ^
Tighten to 48 Nm (35 lb-ft).
4.0L Explorer Sport Trac
3. 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.
4. 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 not welded to the muffler inlet pipe, make sure that the service exhaust coupler is against the
alignment nub and is positioned approximately at the 2 o'clock position facing the muffler. If the
muffler inlet pipe does not have an alignment nub, center the exhaust coupler over the muffler inlet
pipe joint and position it at approximately the 2 o'clock position facing the muffler.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service
and Repair > Page 2557
^ Tighten to 47 Nm (35 lb-ft).
4.6L Explorer Sport Trac
5. 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.
6. 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 not welded to the muffler inlet pipe, make sure that the service exhaust coupler is against the
alignment nub and is positioned approximately at the 2 o'clock position facing the muffler. If the
muffler inlet pipe does not have an alignment nub, center the exhaust coupler over the muffler inlet
pipe joint and position it at approximately the 2 o'clock position facing the muffler. ^
Tighten to 47 Nm (35 lb-ft).
All Vehicles
7. NOTE: Install new exhaust Y-pipe dual catalytic converter-to-muffler assembly gasket and nuts.
Install the exhaust Y-pipe-dual catalytic converter-to-muffler assembly new gasket, bolts and new
nuts. ^
Tighten to 40 Nm (30 lb-ft).
8. Check to see if the exhaust system isolators are at zero load. If the exhaust system isolators are
not at zero load, then carry out the exhaust system
alignment procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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.
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
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: -
The throttle actuator control (TAC) motor is a DC motor controlled by the PCM (requires 2-wires).
- There are 2 designs: parallel and in-line. 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-line design has a
separate motor housing.
- An internal spring is used in both designs to return the throttle plate to a default position. The
default position is typically a throttle angle of 7 to 8 degrees from the hard stop angle.
- The closed throttle plate hard stop is used to prevent the throttle from binding in the bore
(approximately 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.
- 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.
- There is 1 reference voltage and 1 signal return circuit between the PCM and the ETB. The
reference voltage circuit and the signal return circuit is shared with the reference voltage circuits
and signal return circuits used by the APP sensor. There are also 2 TP signal circuits for
redundancy. The redundant TP 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). The TP2 signal reaches a limit of
approximately 4.5 volts at approximately 45 degrees of throttle angle.
Accelerator Pedal Position (APP) Sensor
Depending on the application either a 2-track or 3-track APP sensor is used.
Electronic Throttle Control (ETC) System Strategy
ETC System With A 3-Track APP Sensor Failure Mode And Effects Management (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 2564
ETC System With A 3-Track APP Sensor Failure Mode And Effects Management (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 2565
ETC System With A 2-Track APP Sensor Failure Mode And Effects Management
Electronic Throttle Monitor Operation
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 2566
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 separate monitoring 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, appropriate corrective action is taken.
APP and TP Sensor Inputs
Accelerator Pedal Position (APP) Sensor Check
Throttle Position (TP) Sensor Check
Electronic Throttle Actuator Control (TAC) Output
Electronic TAC Operation Check
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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: > 09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC
P0196/RPM Loss/Slow Idle
Engine Control Module: Customer Interest Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow
Idle
TSB 09-22-6
11/16/09
4.6L ENGINE -CHECK ENGINE LIGHT ON - DTC P0196 - COLD WEATHER DRIVING
CONDITIONS- CALIBRATION UPDATE
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
ISSUE Some 2006-2008 Explorer, Mountaineer and Sport Trac vehicles and equipped with 4.6L
3-V engines may exhibit:
^ Diagnostic trouble code (DTC) P0196 - engine oil temperature (EOT) sensor range/performance
during ice/snow driving conditions.
^ Idle speed dropping below specification, hesitation or loss of RPM with no DTCs stored in the
Powertrain Control Module (PCM).
^ Cruise control surge at approximately 50-60 MPH (80-97 Km/h) in hilly regions Only applies to
vehicles operated in altitudes above 5000 feet (1.52
km).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
If normal Powertrain Controls/Emissions Diagnosis (PC/ED) diagnostics do not resolve the above
vehicle concerns, reprogram the PCM and Transmission Control Module (1CM) to the latest
calibration using IDS release 63.08 and higher. This new calibration is not included in the VCM
2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
VEHICLES EQUIPPED WITH A PCM AND TCM, REQUIRE A COORDINATED
REPROGRAMMING.
THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS
OUTLINED BY THE INTERGRATED DIAGNOSTIC SYSTEM (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 63.08 and higher. This new calibration
is not included in the VCM 2009.9 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:
(1) Choose all Tests and Calibrations.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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: > 09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC
P0196/RPM Loss/Slow Idle > Page 2575
(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
DISCONNECTING 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 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. Brake gently to a complete
stop and hold foot on brake for at least 10 seconds.
g. Repeat Steps (e-f) a total of three (3) 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
092206A 2006-2008 Explorer, 1.0 Hr.
Mountaineer 2007-2008 Explorer Sport Trac: Check DTCs, Reprogram The PCM And TCM
Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor
Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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: > 09-22-6 > Nov > 09 > Engine Controls - MIL
ON/DTC P0196/RPM Loss/Slow Idle
Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0196/RPM
Loss/Slow Idle
TSB 09-22-6
11/16/09
4.6L ENGINE -CHECK ENGINE LIGHT ON - DTC P0196 - COLD WEATHER DRIVING
CONDITIONS- CALIBRATION UPDATE
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
ISSUE Some 2006-2008 Explorer, Mountaineer and Sport Trac vehicles and equipped with 4.6L
3-V engines may exhibit:
^ Diagnostic trouble code (DTC) P0196 - engine oil temperature (EOT) sensor range/performance
during ice/snow driving conditions.
^ Idle speed dropping below specification, hesitation or loss of RPM with no DTCs stored in the
Powertrain Control Module (PCM).
^ Cruise control surge at approximately 50-60 MPH (80-97 Km/h) in hilly regions Only applies to
vehicles operated in altitudes above 5000 feet (1.52
km).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
If normal Powertrain Controls/Emissions Diagnosis (PC/ED) diagnostics do not resolve the above
vehicle concerns, reprogram the PCM and Transmission Control Module (1CM) to the latest
calibration using IDS release 63.08 and higher. This new calibration is not included in the VCM
2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
VEHICLES EQUIPPED WITH A PCM AND TCM, REQUIRE A COORDINATED
REPROGRAMMING.
THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS
OUTLINED BY THE INTERGRATED DIAGNOSTIC SYSTEM (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 63.08 and higher. This new calibration
is not included in the VCM 2009.9 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:
(1) Choose all Tests and Calibrations.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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: > 09-22-6 > Nov > 09 > Engine Controls - MIL
ON/DTC P0196/RPM Loss/Slow Idle > Page 2581
(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
DISCONNECTING 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 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. Brake gently to a complete
stop and hold foot on brake for at least 10 seconds.
g. Repeat Steps (e-f) a total of three (3) 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
092206A 2006-2008 Explorer, 1.0 Hr.
Mountaineer 2007-2008 Explorer Sport Trac: Check DTCs, Reprogram The PCM And TCM
Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor
Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 2582
Engine Control Module: Locations
View 151-1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 2583
View 151-4
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 2584
View 151-8
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 2585
View 151-10
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 2588
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 2589
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 2590
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 2591
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 2592
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 2593
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 2594
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 terminal by pulling each wire at the end of the connector.
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2595
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2596
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2597
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information and Instructions > Page 2598
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information and Instructions > Page 2599
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.
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, barrel squeeze tool handles appropriate 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.
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2600
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
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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 2601
Engine Control Module: Connector Views
C175B (Part 1)
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2602
C175B (Part 2)
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2603
C175E (Part 1)
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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 2604
C175E (Part 2)
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2605
C175E (Part 3)
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2606
C175T (Part 1)
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2607
C175T (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 >
Procedures
Engine Control Module: Procedures
FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM)
Description
The EEPROM is contained in an integrated circuit 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 PI635 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 (V8-4.6L (2008))
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 >
Procedures > Page 2610
Engine Control Module: Removal and Replacement
POWERTRAIN CONTROL MODULE (PCM)
A/C Tube Brackets
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Procedures > Page 2611
PCM
Removal
All vehicles
1. NOTE: 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 3. Disconnect the RH front wheel speed sensor electrical connector. Remove the nut(s)
and position the A/C tube bracket(s) 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
bracket(s) and install the nut(s). Connect the RH front wheel speed sensor electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair >
Procedures > Page 2612
- 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.
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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 (V8-4.6L (2008))
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 2616
Main Relay (Computer/Fuel System): Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Modules - Emission Control Systems > EGR Control Module > Component Information > Locations
View 151-7
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Modules - Emission Control Systems > EGR Control Module > Component Information > Locations > Page 2621
C1450
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Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations
Fuel Pump Control Unit: Locations
View 151-24
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Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 2626
View 151-27
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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 2627
C4033
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Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 2628
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 (V8-4.6L (2008))
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Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations
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Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2632
Fuel Pump Relay: Testing and Inspection
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Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 2636
Main Relay (Computer/Fuel System): Testing and Inspection
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Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations
View 151-13
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Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 2642
C2040
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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 2643
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
amount of torque requested by the operator. Depending on the application either a 2-track or
3-track APP sensor is used.
2-Track APP Sensor
2-Track APP Sensor
There are 2 pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive
slope (increasing angle, increasing voltage), but are offset and increase at different rates. The 2
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. If a concern is present with one of the circuits the other input is used. There are 2
reference voltage circuits, 2 signal return circuits, and 2 signal circuits (a total of 6 circuits and pins)
between the PCM and the APP sensor assembly. The reference voltage circuits and the signal
return circuits are shared with the reference voltage circuit and signal return circuit used by the
electronic throttle body (ETB) throttle position sensor. The pedal position signal is converted 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.
3-Track APP Sensor
Typical 3-Track APP Sensor
There are 3 pedal position signals in the sensor. Signal 1, APP1, has a negative slope (increasing
angle, decreasing voltage) and signals 2 and 3, 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. 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. If a concern is present with one of the circuits
the other inputs are used. The pedal position signal is converted 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. There are 2 reference voltage circuits, 2 signal return circuits, and 3 signal
circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. The
reference voltage circuits and the signal return circuits are shared with the reference voltage circuit
and signal return circuit used by the electronic throttle body (ETB) throttle position sensor.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations
Air Flow Meter/Sensor: Locations
View 151-8
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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 2647
View 151-9
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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 2648
C1454
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 2649
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
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Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2650
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 (V8-4.6L (2008))
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Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2651
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 sensor.
- To install, tighten to 2 Nm (18 lb-in).
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft
Position Sensor 1
View 151-9
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Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft
Position Sensor 1 > Page 2656
View 151-9
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Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft
Position Sensor 1 > Page 2657
View 151-7
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Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft
Position Sensor
C180
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Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft
Position Sensor > Page 2660
C1366
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft
Position Sensor > Page 2661
C1367
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Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page
2662
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.
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Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page
2663
Camshaft Position Sensor: Service and Repair
CAMSHAFT POSITION (CMP) SENSOR
Removal and Installation
RH side
1. Remove the air cleaner (ACL) outlet pipe.
Both sides
2. Disconnect the camshaft position (CMP) sensor electrical connector. 3. Remove the bolt and the
CMP sensor.
- To install, tighten to 10 Nm (89 lb-in).
4. To install, reverse the removal procedure.
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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.
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Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Diagrams
C1064
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Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations
Crankshaft Position Sensor: Locations
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Crankshaft Position Sensor: Diagrams
C101
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C1120
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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 decelerations between teeth.
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Crankshaft Position Sensor: Service and Repair
CRANKSHAFT POSITION (CKP) SENSOR
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Removal and Installation
1. With vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt. 3.
Disconnect the A/C compressor coil electrical connector. 4. Detach the battery cable retainer from
the A/C compressor stud bolts. 5. Remove the nut and detach the A/C tube bracket.
- To install, tighten to 10 Nm (89 lb-in).
6. Remove the stud bolts and position the A/C compressor aside.
- To install, tighten to 25 Nm (18 lb-ft).
7. Disconnect the crankshaft position (CKP) sensor electrical connector. 8. Remove the bolt and
the CKP sensor.
- To install, tighten to 10 Nm (89 lb-in).
9. To install, reverse the removal procedure.
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2683
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.
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Engine Temperature Sensor: Service and Repair
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Removal and Installation
1. Disconnect the battery ground cable. 2. Remove the intake manifold. 3. Disconnect the cylinder
head temperature (CHT) sensor electrical connector. 4. Remove and discard the CHT sensor.
- To install, tighten to 26 Nm 19 lb-ft).
5. To install, reverse the removal procedure.
- Do not reuse the CHT sensor. Install a new sensor.
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Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation
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.
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Fuel Level Sensor: Service and Repair
FUEL LEVEL SENDER
Removal
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working
on or near any fuel-related component. Highly flammable mixtures are always present and may be
ignited. Failure to follow these instructions may result in serious personal injury.
1. Remove the fuel pump. 2. Remove the screw and the fuel level sender cover.
3. NOTE: Note the routing of the fuel level sender wire for installation.
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Remove the heat shrink tube covering the fuel level sender wire electrical connector.
4. Disconnect the fuel level sender wire electrical connector.
5. NOTE: Note the routing of the fuel level sender ground wire for installation.
Disconnect the ground wire and remove the screw and lift up to remove the fuel level sender.
Installation
1. Route the fuel level sender ground wire along the fuel pump body.
2. Route the fuel level sender wire through the center of the fuel pump.
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3. NOTE: Both fuel gauge sending wires must be routed behind the metal sending unit plate.
Hook the fuel level sender on the fuel pump and install and tighten the screw. Connect the fuel
level sender unit ground wire.
4. Slide the heat shrink tube onto the wire harness and connect the fuel level sender wire electrical
connector.
5. WARNING: Do not use an open flame to shrink the heat shrink tube. Use a heat gun only. Fuel
residue may be ignited if an open flame is
used. Failure to follow this instruction may result in serious personal injury.
Using a heat gun, shrink the heat shrink tube.
6. Install the fuel level sender cover and screw and tighten the screw. 7. Install the fuel pump.
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Fuel Tank Pressure Sensor: Locations
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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.
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Fuel Tank Pressure Sensor: Service and Repair
FUEL TANK PRESSURE SENSOR
Removal and Installation
WARNING:
- When working on or near the evaporative emission (EVAP) system, disconnect the battery ground
cable from the battery. The EVAP system contains fuel vapor and condensed fuel vapor, so an
electrical spark may cause a fire or explosion. Failure to follow this instruction may result in serious
personal injury.
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious personal injury.
1. Remove the evaporative emission (EVAP) canister. 2. Remove the fuel tank shield from the fuel
tank.
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3. Disconnect the fuel tank pressure (FTP) sensor electrical connector. 4. Disconnect the 3 FTP
sensor and tube assembly quick connect couplings from the fuel pump module and the vapor vent
valves. 5. Remove the FTP sensor and tube assembly. 6. To install, reverse the removal
procedure. 7. Leak test the EVAP system. 8. Carry out the evaporative emission repair verification
drive cycle.
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Intake Air Temperature Sensor: Locations
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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
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fuel, spark, and air flow.
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 above. 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.
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
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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.
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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.
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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.
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C104
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Page 2719
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.
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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.
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Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #11
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Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #21
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Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #22
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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.
Universal HO2S
The universal HO2S, sometimes referred to as a wideband oxygen sensor, uses the typical HO2S
combined with a current controller in the PCM to infer an air/fuel ratio relative to the stoichiometric
air/fuel ratio. This is accomplished by balancing the amount of oxygen ions pumped in or out of a
measurement chamber within the sensor. The typical HO2S within the universal HO2S is used to
detect the oxygen content of the exhaust gas in the measurement chamber. The oxygen content
inside the measurement chamber is maintained at the stoichiometric air/fuel ratio by pumping
oxygen ions in and out of the measurement chamber. As the exhaust gasses get richer or leaner,
the amount of oxygen that must be pumped in or out to maintain a stoichiometric air/fuel ratio in the
measurement chamber varies in proportion to the air/fuel ratio. The amount of current required to
pump the oxygen ions in or out of the measurement chamber is used to measure the air/fuel ratio.
The measured air/fuel ratio is actually the output from the current controller in the PCM and not a
signal that comes directly from the sensor.
The universal HO2S also uses a self-contained reference chamber to make sure an oxygen
differential is always present. The oxygen for the reference chamber is supplied by pumping small
amounts of oxygen ions from the measurement chamber into the reference chamber. The universal
HO2S does not need access to outside air.
Part to part variance is compensated for by placing a resistor in the connector. This resistor is used
to trim the current measured by the current controller in the PCM.
Embedded with the sensing element is the universal H02S heater. The heater allows the engine to
enter closed loop operation sooner. The heating element heats the sensor to a temperature of
780°C (1,436°F). The VPWR circuit supplies voltage to the heater. The PCM controls the heater on
and off by providing the ground to maintain the sensor at the correct temperature for maximum
accuracy.
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Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S)
HEATED OXYGEN SENSOR (HO2S)
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Oxygen Sensor (HO2S) > Page 2741
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.
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Oxygen Sensor (HO2S) > Page 2742
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.
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor (HO2S) > Page 2743
Oxygen Sensor: Service and Repair Catalyst Monitor Sensor
CATALYST MONITOR SENSOR
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Oxygen Sensor (HO2S) > Page 2744
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.
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Oxygen Sensor (HO2S) > Page 2745
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.
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Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations
View 151-2
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Page 2749
C121
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Page 2750
Power Steering Pressure Switch: Description and Operation
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.
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.
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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
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The tube mounted differential pressure feedback EGR sensor is identical in operation as the larger
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.
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations
Throttle Position Sensor: Locations
View 151-7
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View 151-9
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C189
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Throttle Position Sensor: Description and Operation
Electronic Throttle Body (ETB) Throttle Position Sensor
The ETB throttle position sensor has 2 signal circuits in the sensor for redundancy. The redundant
ETB throttle position signals are required for increased monitoring. The first ETB throttle 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). The 2 ETB throttle 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. The reference voltage circuit
and the signal return circuit is shared with the reference voltage circuits and signal return circuits
used by the APP 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
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Throttle Position Sensor: Service and Repair
THROTTLE POSITION (TP) SENSOR
Heated PCV Fitting
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Throttle Position (TP) Sensor
Removal
Vehicles equipped with a 4.6L (3V) engine 1. Remove the air cleaner (ACL) outlet pipe. 2. Remove
the bolts and position the heated 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 throttle position (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.
Installation
All vehicles
1. CAUTION:
- Do not reuse the throttle position (TP) sensor and screws. A new TP sensor and screws must be
installed. Failure to follow this instruction may result in poor engine performance.
- Do not use a high-speed driver to install the new screws or damage to the throttle position (TP)
sensor may 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.
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- 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 ACL outlet pipe.
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Locations
Transmission Position Switch/Sensor: Locations
View 151-7
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Locations > Page 2767
View 151-11
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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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
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Diagrams > Diagram Information and Instructions > Page 2770
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
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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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
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Diagrams > Diagram Information and Instructions > Page 2772
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
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Symbols (Part 2)
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Diagrams > Diagram Information and Instructions > Page 2774
Symbols (Part 3)
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Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 2775
Symbols (Part 4)
Symbols (Part 5)
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Diagrams > Diagram Information and Instructions > Page 2776
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 terminal by pulling each wire at the end of the connector.
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Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
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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
3 = Splice tape
4 = Harness tape
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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.
3. lnstall 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 seat wire splice.
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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.
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 6.35mm (1/4 in) 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.
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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.
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, barrel squeeze tool handles appropriate 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.
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The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
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C167
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Transmission Position Switch/Sensor: Adjustments
Transmission Range (TR) Sensor Adjustment - 5R55S
Adjust
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever 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 digital transmission range (TR) sensor electrical
connector.
4. Disconnect the digital TR sensor electrical connector.
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5. Remove the selector lever cable end from the manual control lever.
6. Remove the outer manual control lever nut and the 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 lb-inch).
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9. Install the outer manual lever and nut.
^ Tighten to 48 Nm (35 lb-ft).
10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable
bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable
to make sure that it is locked into the selector lever cable 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 selector lever cable end is correctly installed.
Install the selector lever cable end onto the manual control lever.
11. Reconnect the digital TR sensor electrical connector.
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12. Move the rubber boot back over the TR electrical connector.
13. NOTE: If the selector lever cable shield is loose on the selector lever cable, replace the selector
lever cable shield.
Install the selector lever cable shield.
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.
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Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Page 2788
Transmission Position Switch/Sensor: Service and Repair
Digital Transmission Range (TR) Sensor - 5R55S
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by
prying on the side of the selector lever cable shield closest to the boot, then sliding the selector
lever
cable shield away from the boot.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 2789
3. Move the rubber boot back to gain access to the digital transmission range (TR) sensor electrical
connector.
4. Disconnect the digital TR sensor electrical connector.
5. Remove the selector lever cable from the manual control lever.
6. Remove the outer manual control lever.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 2790
7. Remove the digital TR sensor.
Installation
1. CAUTION: The digital transmission range (TR) 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. ^
Tighten to 8 Nm (71 lb-inch).
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Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Page 2791
3. Install the outer manual lever.
^ Tighten to 48 Nm (35 lb-ft).
4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen
for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that
it is locked into the selector lever cable 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
selector lever cable end is correctly installed.
Install the selector lever cable to the manual control lever.
5. Connect the digital TR sensor electrical connector.
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6. Move the rubber boot back over the TR sensor electrical connector.
7. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector
lever cable shield.
Install the selector lever cable shield.
8. Verify that the selector lever cable is adjusted correctly.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Vehicle Speed Sensor: Description and Operation
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.
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 (V8-4.6L (2008))
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
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Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description
and Operation > Page 2800
The tube mounted differential pressure feedback EGR sensor is identical in operation as the larger
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.
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Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations
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Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 2805
C2040
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 2806
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
amount of torque requested by the operator. Depending on the application either a 2-track or
3-track APP sensor is used.
2-Track APP Sensor
2-Track APP Sensor
There are 2 pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive
slope (increasing angle, increasing voltage), but are offset and increase at different rates. The 2
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. If a concern is present with one of the circuits the other input is used. There are 2
reference voltage circuits, 2 signal return circuits, and 2 signal circuits (a total of 6 circuits and pins)
between the PCM and the APP sensor assembly. The reference voltage circuits and the signal
return circuits are shared with the reference voltage circuit and signal return circuit used by the
electronic throttle body (ETB) throttle position sensor. The pedal position signal is converted 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.
3-Track APP Sensor
Typical 3-Track APP Sensor
There are 3 pedal position signals in the sensor. Signal 1, APP1, has a negative slope (increasing
angle, decreasing voltage) and signals 2 and 3, 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. 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. If a concern is present with one of the circuits
the other inputs are used. The pedal position signal is converted 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. There are 2 reference voltage circuits, 2 signal return circuits, and 3 signal
circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. The
reference voltage circuits and the signal return circuits are shared with the reference voltage circuit
and signal return circuit used by the electronic throttle body (ETB) throttle position sensor.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Air Flow Meter/Sensor: Locations
View 151-8
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Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2810
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Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2811
C1454
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2812
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
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Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2813
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 (V8-4.6L (2008))
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Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2814
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 sensor.
- To install, tighten to 2 Nm (18 lb-in).
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations
Fuel Pressure Sensor/Switch: Locations
View 151-7
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Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page
2818
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Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page
2819
C173
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page
2820
Fuel Pressure Sensor/Switch: 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 (V8-4.6L (2008))
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2821
Fuel Pressure Sensor/Switch: Service and Repair
FUEL RAIL PRESSURE AND TEMPERATURE SENSOR
Removal and Installation
WARNING:
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious personal injury.
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the
fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under
high pressure, even when the engine is not running. Failure to follow this instruction may result in
serious personal injury.
1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel
rail pressure and temperature sensor electrical connector. 4. Disconnect the fuel rail pressure and
temperature sensor vacuum hose connector. 5. Remove the 2 bolts and the fuel rail pressure and
temperature sensor.
- To install, tighten to 6 Nm (53 lb-in).
6. To install, reverse the removal procedure.
- Inspect the O-ring seal and install a new O-ring seal if necessary.
- Lubricate the O-ring seal with clean engine oil.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations
Fuel Temperature Sensor: Locations
View 151-7
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Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 2825
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Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 2826
C173
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Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 2827
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 (V8-4.6L (2008))
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 2828
Fuel Temperature Sensor: Service and Repair
FUEL RAIL PRESSURE AND TEMPERATURE SENSOR
Removal and Installation
WARNING:
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious personal injury.
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the
fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under
high pressure, even when the engine is not running. Failure to follow this instruction may result in
serious personal injury.
1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel
rail pressure and temperature sensor electrical connector. 4. Disconnect the fuel rail pressure and
temperature sensor vacuum hose connector. 5. Remove the 2 bolts and the fuel rail pressure and
temperature sensor.
- To install, tighten to 6 Nm (53 lb-in).
6. To install, reverse the removal procedure.
- Inspect the O-ring seal and install a new O-ring seal if necessary.
- Lubricate the O-ring seal with clean engine oil.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations
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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 2832
C282
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 2833
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, Roadside Emergencies for the location of the IFS switch.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 2834
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations
Throttle Position Sensor: Locations
View 151-7
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Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2838
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Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2839
C189
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 2840
Throttle Position Sensor: Description and Operation
Electronic Throttle Body (ETB) Throttle Position Sensor
The ETB throttle position sensor has 2 signal circuits in the sensor for redundancy. The redundant
ETB throttle position signals are required for increased monitoring. The first ETB throttle 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). The 2 ETB throttle 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. The reference voltage circuit
and the signal return circuit is shared with the reference voltage circuits and signal return circuits
used by the APP 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
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Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2841
Throttle Position Sensor: Service and Repair
THROTTLE POSITION (TP) SENSOR
Heated PCV Fitting
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2842
Throttle Position (TP) Sensor
Removal
Vehicles equipped with a 4.6L (3V) engine 1. Remove the air cleaner (ACL) outlet pipe. 2. Remove
the bolts and position the heated 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 throttle position (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.
Installation
All vehicles
1. CAUTION:
- Do not reuse the throttle position (TP) sensor and screws. A new TP sensor and screws must be
installed. Failure to follow this instruction may result in poor engine performance.
- Do not use a high-speed driver to install the new screws or damage to the throttle position (TP)
sensor may 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2843
- 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 ACL outlet pipe.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor
1
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Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor
1 > Page 2849
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Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor
1 > Page 2850
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Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor
C180
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Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor
> Page 2853
C1366
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Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor
> Page 2854
C1367
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2855
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2856
Camshaft Position Sensor: Service and Repair
CAMSHAFT POSITION (CMP) SENSOR
Removal and Installation
RH side
1. Remove the air cleaner (ACL) outlet pipe.
Both sides
2. Disconnect the camshaft position (CMP) sensor electrical connector. 3. Remove the bolt and the
CMP sensor.
- To install, tighten to 10 Nm (89 lb-in).
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations
Crankshaft Position Sensor: Locations
View 151-8
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2860
View 151-9
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2861
Crankshaft Position Sensor: Diagrams
C101
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2862
C1120
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2863
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 decelerations between teeth.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2864
Crankshaft Position Sensor: Service and Repair
CRANKSHAFT POSITION (CKP) SENSOR
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2865
Removal and Installation
1. With vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt. 3.
Disconnect the A/C compressor coil electrical connector. 4. Detach the battery cable retainer from
the A/C compressor stud bolts. 5. Remove the nut and detach the A/C tube bracket.
- To install, tighten to 10 Nm (89 lb-in).
6. Remove the stud bolts and position the A/C compressor aside.
- To install, tighten to 25 Nm (18 lb-ft).
7. Disconnect the crankshaft position (CKP) sensor electrical connector. 8. Remove the bolt and
the CKP sensor.
- To install, tighten to 10 Nm (89 lb-in).
9. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Part 1
Part 2
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations
View 151-8
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2873
C108
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2874
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 (V8-4.6L (2008))
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 (KOEO)..............................................................................................................
.............................................207-276 kPa (30-40 psi) Engine running.................................................
..................................................................................................................................207-276 kPa
(30-40 psi)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Specifications > Page 2879
Fuel Pressure: Testing and Inspection
FUEL SYSTEM PRESSURE TEST
Special Tool(s)
Special Tool(s)
WARNING:
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious personal injury.
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the
fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under
high pressure, even when the engine is not running. Failure to follow this instruction may result in
serious 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 component. Highly flammable mixtures are always
present and may be ignited. Failure to follow these instructions may result in serious personal
injury.
- When handling fuel, always observe fuel handling precautions and be prepared in the event of
fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources.
Failure to follow these instructions may result in serious personal injury.
1. Disconnect the fuel supply tube-to-fuel rail spring lock coupling.
2. NOTE: 4.6L shown, 4.0L similar.
Install the special tool in line between the fuel supply tube and fuel rail.
3. NOTE: The inertia fuel shutoff (IFS) switch electrical connector was disconnected during fuel
system pressure release.
Connect the IFS switch electrical connector.
4. 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.
5. Test the fuel system pressure to make sure it is within the specified range.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Specifications > Page 2880
6. NOTE:
- 4.6L shown, 4.0L similar.
- Open the drain valve slowly to relieve the fuel system pressure. This may drain fuel from the
system. Place the fuel in a suitable container.
Upon completion of the fuel system pressure test, open the drain valve on the special tool and
relieve the fuel system pressure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Specifications
Idle Speed: Specifications
Typical Diagnostic Reference Value
Measured/PID Values 630 - 850 RPM ................................................................................................
...................................................................................................... Hot Idle
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Coolant Expansion Tank
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
Air Filter Element > Component Information > Service and Repair > Page 2888
Intake Air System Components (4.0L SOHC)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
Air Filter Element > Component Information > Service and Repair > Page 2889
Intake Air System Components - 4.6L (3V)
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 (ACL) outlet pipe.
Vehicles equipped with a 4.6L (3V) engine
2. Detach the wiring harness retainer from the coolant expansion tank.
All vehicles
3. Loosen the clamp and disconnect the ACL outlet pipe from the ACL. 4. Unclip and remove the
ACL cover. 5. Remove the ACL.
6. NOTE: Clean the inside of the ACL tray.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious personal injury.
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the
fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under
high pressure, even when the engine is not running. Failure to follow this instruction may result in
serious 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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order >
Component Information > Specifications
Firing Order: Specifications
Firing order...........................................................................................................................................
...........................................................1-3-7-2-6-5-4-8
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 before top dead center (BTDC)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Service and Repair
Ignition Cable: Service and Repair
Ignition Components RH Side
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Service and Repair > Page 2903
Ignition Components LH Side
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions
Spark Plug: Technical Service Bulletins Ignition System - Spark Plug Removal Instructions
TSB 08-7-6
04/14/08
SPARK PLUG REMOVAL INSTRUCTIONS - 4.6L 3V/5.4L 3V16.8L 3V
FORD: 2005-2008 Mustang 2004-2008 F-150 2005-2008 Expedition, F-Super Duty 2006-2008
Explorer, F-53 Motorhome Chassis 2007-2008 Explorer Sport Trac
LINCOLN: 2005-2008 Navigator 2006-2008 Mark LT
MERCURY: 2006-2008 Mountaineer
This article supersedes TSB 08-1-9 to update Vehicle Applications, Service Procedure and Part
List.
ISSUE Some 2004-2008 F-150, 2006-2008 Mark LT, 2005-2008 F-Super Duty, Expedition, and
Navigator, with 5.4L 3-V engine; 2005-2008 Mustang, 2006-2008 Explorer, Mountaineer, and
2007-2008 Explorer Sport Trac with 4.6L 3-V engine; 2005-2008 F-Super Duty, 2006-2008 and
F-Stripped Chassis, with 6.8L 3-V engine may experience difficulty with spark plug removal. This
may cause damage to the spark plug and leave part of the spark plug in the cylinder head. Affected
engine build dates are as follows: 5.4L 3-V and 6.8L 3-V before 10/9/07, 4.6L 3-V before 11/30/07.
ACTION Refer to the following Service Procedure for techniques to remove the spark plugs and
extract broken spark plugs.
SERVICE PROCEDURE
The engine build date can be read on the left hand cam cover information sticker.
To remove spark plugs without damage, it is necessary to adhere exactly to this procedure before
removal is attempted.
CAUTION
DO NOT REMOVE PLUGS WHEN THE ENGINE IS WARM OR HOT. THE ENGINE MUST BE AT
ROOM TEMPERATURE WHEN PERFORMING SPARK PLUG SERVICE. REMOVING THE
SPARK PLUGS FROM A WARM/HOT ENGINE INCREASES THE CHANCE THE THREADS
COULD BE DAMAGED.
Spark Plug Removal Procedure
1. Remove the coil-on-plug assemblies and thoroughly blow out the spark plug wells and
surrounding valve cover area with compressed air.
2. Back out the spark plugs no more than 1/8 to 1/4 of a turn. Using Motorcraft(R) Carburetor
Tune-Up Cleaner, fill the spark plug well just above where the jamb nut hex sits (1/2 - 3/4
teaspoon). A minimum period of 15 minutes of soak time is required. The cleaner will wick down to
the ground electrode shield and soften the carbon deposits in this time. DO NOT WORK the spark
plug back and forth at this point.
NOTE
COMPLETELY REVIEW THE PRODUCT LABEL FOR THE MOTORCRAFT CARBURETOR
TUNE-UP CLEANER PRODUCT - USE AT ROOM TEMPERATURE AND SHAKE WELL.
CAUTION
EXCESSIVE MOTORCRAFT(R) CARBURETOR TUNE-UP CLEANER, OR REPEATING THE
PROCESS SEVERAL TIMES WITH TOO MUCH CLEANER FLUID, COULD INTRODUCE
ENOUGH LIQUID VOLUME TO HYDRO-LOCK THE ENGINE.
CAUTION
DO NOT USE AIR OR POWER TOOLS FOR SPARK PLUG REMOVAL. SPARK PLUGS MUST
ONLY BE REMOVED WITH HAND TOOLS.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2908
3. Tighten, and then loosen the spark plug, working the plug back and forth. Some screeching and
high effort may be noticed. The expected removal torque is about 33 lb-ft (45 N.m). Repeat the
back and forth turning as needed until turning effort is reduced, and remove the spark plugs.
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP. (Figure 1)
Separated/Broken Spark Plug Removal
If the spark plug separates after following the Spark Plug Removal Procedure, it will fail in one of
three modes. Refer to the appropriate removal procedure as required.
a. Mode 1: The ground electrode shield is left behind as an empty shell. (Figure 2)
b. Mode 2: The entire porcelain insulator and ground electrode shield remains in the cylinder head.
(Figure 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2909
c. Mode 3: The upper section of porcelain broke off with remaining porcelain left inside the ground
shield. (Figure 4)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2910
Flowchart of procedure. (Figure 5)
Mode 1 Procedure:
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2911
Use Rotunda special service tool 303-1203 to remove an empty ground electrode shield from the
cylinder head. (Figure 6)
NOTE
THIS TOOL IS ONLY DESIGNED TO WORK WITH AN EMPTY GROUND ELECTRODE SHIELD.
IF PORCELAIN REMAINS, PROCEED TO MODE 2 OR 3 REMOVAL.
1. Modify vacuum cap to a 3/8" (10 mm) length for each ground electrode shield that needs to be
removed. (Figure 7)
2. Use the installation rod (J) provided with service tool 303-1203 update to install the modified
vacuum cap. Push the cap into the ground shield down to the electrode strap. This will plug and
protect the combustion chamber from contamination. (Figure 7)
3. Thread-tap the ground electrode shield using a 9.0 x 1.0 mm plug tap (tap profile is about 3-4
reduced diameter threads on the tip end).
a. Coat the end of the tap with general purpose grease. (Figure 8)
b. Turn the tap about 3 to 4 turns into the ground electrode shield. Back the tap up frequently to
break chips and avoid cut material from coiling-up in the spark plug well. A tap socket adaptor (K)
is provided with service tool 303-1203 update to connect the tap to a 3/8" socket
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2912
drive.
CAUTION
DO NOT ATTEMPT TO REMOVE THE GROUND ELECTRODE SHIELD WITH THE TAP AND
WRENCH. THE TAP MAY BREAK IF THIS IS ATTEMPTED.
4. Thread Rotunda special service tool 303-1203 into the ground electrode shield. (Figure 9)
a. Install the stepped end of the tool pilot bushing into the spark plug well ensuring it bottoms out.
b. Screw the center shank into the ground electrode shield. Do not over tighten the shank, to
prevent thread stripping.
c. Install the nylon washer and jack nut until finger tight.
d. Turn the jack nut until the ground electrode is freed from the cavity and withdraw the tool
assembly.
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP.
Mode 2 Procedure:
1. Add an additional 1/2 teaspoon Motorcraft® Carburetor Tune-Up Cleaner fluid into spark plug
well and allow 15 minutes of soak time.
2. Using long-reach nose pliers grasp and remove the porcelain with an up and down motion taking
care not to fracture the porcelain.
3. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder
head.
Mode 3 Procedure:
CAUTION
DO NOT DRIVE PORCELAIN DOWN INTO THE GROUND SHIELD WITH A PUNCH AS
FRAGMENTS MAY ENTER THE COMBUSTION CHAMBER.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2913
Use Rotunda special service tool kit 303-1398 to remove porcelain broken inside the ground
electrode shield. (FIGURE 10)
Porcelain Removal - Preparation
CAUTION
THE ENGINE AND THE BONDING ADHESIVE MUST BE ROOM TEMPERATURE OF 70 °F (21
°C) OR HIGHER FOR PROPER CURE AND BOND STRENGTH. VERIFY EXPIRATION DATE OF
ADHESIVE.
CAUTION
DO NOT REUSE PINS. THIS ENSURES THE CORRECT SURFACE CHARACTERISTICS FOR
BONDING.
1. Remove any remaining electrode material from broken porcelain with long nose reach pliers.
2. Spray Motorcraft® Metal Brake Parts Cleaner into the porcelain hole for 2-4 seconds using the
straw nozzle supplied with the brake cleaner can.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2914
3. Insert a pin (A) into the collet (B). Screw the collet onto the threaded rod (C). Install the
assembled collet, pin, and threaded rod into the steel tool pilot (F). (Figures 11 and 12)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2915
4. Retract the collet and pin into the steel tool pilot, protecting the pin. (Figures 13 and 14)
NOTE
PIN TIP DAMAGE OR BENT PINS WILL PREVENT INSERTION INTO THE PORCELAIN.
5. Insert the completed assembly into the spark plug well and fully engage the pin into the
porcelain. (Figure 15)
6. Spray Motorcraft(R) Metal Brake Parts Cleaner 2-4 seconds between the spark plug well and
steel tool pilot. The steel tool pilot must be lifted up approximately 1/2" to allow brake cleaner to
flood the porcelain and pin.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2916
7. Scrub the porcelain inside diameter by moving the threaded rod up and down vigorously. Take
care making sure the pin does not disengage the porcelain. (Figure 16).
8. Repeat Steps 6 and 7.
9. Remove the tool assembly. Again flood the porcelain with Motorcraft(R) Metal Brake Parts
Cleaner for 2-4 seconds, then blow out the entire spark plug well and porcelain with dry
compressed air.
NOTE
CLEAN AND DRY COMPONENTS ARE KEY TO BONDING THE PIN TO THE PORCELAIN.
10. Repeat Steps 1-9 to prepare remaining porcelain fragments as needed.
11. Disassemble the collet and pin from the threaded rod. Dry the tools thoroughly with dry
compressed air.
Porcelain Removal - Bonding Process
CAUTION
USE CARE TO PREVENT BONDING AGENT FROM CONTACTING THREADS IN CYLINDER
HEAD.
NOTE
WORKING TIME LIMIT OF LOCTITE(R) 638(TM) RETAINING COMPOUND IS 5 MINUTES.
1. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to opposite sides of a clean and dry
applicator (H). Excessive amounts of Loctite(R) 638(TM) are being used if it drips off the applicator.
(Figure 17)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2917
2. Insert applicator into the porcelain and move applicator up and down 1/2" (13 mm) while turning
to spread the Loctite® 638TM on the inside of the porcelain. (Figure 18).
3. Add additional Loctite(R) 638(TM), repeating Steps 1 and 2.
4. Clean the applicator with Motorcraft(R) Metal Brake Parts Cleaner before the bonding agent
starts to cure.
5. Reassemble a dry and clean collet and pin assembly.
6. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to the pin. Excessive amounts of
Loctite® 638TMare being used if it drips off the pin.
7. Retract the collet and pin into the steel tool pilot to protect the Loctite(R) 638(TM) coated pin.
8. Insert the completed assembly into spark plug well and fully engage the pin into the porcelain
with a twisting motion to spread the bonding agent.
9. Add additional Loctite® 638TM, repeating Steps 6-8.
10. Leave the pin fully inserted in the porcelain while the adhesive cures. Replace the steel tool
pilot with the aluminum alignment sleeve (G), Figure 9, to support the threaded rod while the
adhesive cures if additional porcelain fragments are present in other cylinders. (Figure 19).
CAUTION
A MINIMUM 1 HOUR CURING TIME AT 70 °F (21 °C) DEGREES IS REQUIRED BEFORE
EXTRACTION IS ATTEMPTED.
11. Allow the Loctite(R) 638(TM) to cure for a minimum of one hour at 70 °F (21 °C).
12. Repeat the bonding process for remaining cylinders as needed.
Porcelain Removal - Extraction
1. After a minimum of one hour curing at 70 °F (21 °C), install the steel pilot tool over the threaded
rod.
2. Install the washer and jack nut until finger tight against the tool pilot bushing.
CAUTION
ONLY THE STEEL PILOT TOOL IS ACCEPTABLE FOR USE IN PORCELAIN REMOVAL.
3. While holding the end of the threaded rod with a wrench, tighten the jack nut until the porcelain is
free of the ground electrode.
4. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder
head.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2918
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP. (FIGURE 7)
Porcelain Removal - Pin Slipped Out
In the unlikely event that the pin does not remove the broken porcelain, this process can be
repeated.
Key elements to success are:
^ Clean and dry porcelain
^ Sufficient Loctite® 638TM Retaining Compound spread uniformly
^ Loctite(R) 638(TM) cure time and temperature
^ Preventing the threaded rod from rotating while removing the porcelain
Replacement Supplies
Replacement kit components and additional kit consumables (Loctite(R) 638TM Retaining
Compound and pins) can be obtained by calling 1-800-ROTUNDA, Option 5.
Parts Block
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
MT080706 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
12405 01
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (not adjustable)............................................................................................................
...................................1.02-1.28 mm (0.040-0.050 in)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > General Specifications > Page 2921
Torque Specifications
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 2922
Spark Plug: Application and ID
Item.......................................................................................................................................................
..............................................................Specification
Spark plug type (early build - black coil boot).......................................................................................
....................................................................PZT-14F Spark plug type (late build - brown coil boot)....
....................................................................................................................................................HJFS
-24FP
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 2923
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.
^
Install new spark plugs.
4. Inspect for normal burning.
^ Check for light tan or gray deposits on the firing tip.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 2924
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(R) 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 a 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.
^ Install new spark plugs.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 2925
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 2926
Spark Plug: Service and Repair
Ignition Components RH Side
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 2927
Ignition Components LH Side
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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.
Compression Pressure Limit Chart (Part 1)
Compression Pressure Limit Chart (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications > Page 2931
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 (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications > Page 2932
Compression Pressure Limit Chart (Part 2)
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
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance >
System Information > Specifications
Valve Clearance: Specifications
Valve Clearance
This engine is equipped with hydraulic lash adjusters. No adjustment is required.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor
> Component Information > Locations
View 151-13
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor
> Component Information > Locations > Page 2940
C2040
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor
> Component Information > Locations > Page 2941
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
amount of torque requested by the operator. Depending on the application either a 2-track or
3-track APP sensor is used.
2-Track APP Sensor
2-Track APP Sensor
There are 2 pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive
slope (increasing angle, increasing voltage), but are offset and increase at different rates. The 2
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. If a concern is present with one of the circuits the other input is used. There are 2
reference voltage circuits, 2 signal return circuits, and 2 signal circuits (a total of 6 circuits and pins)
between the PCM and the APP sensor assembly. The reference voltage circuits and the signal
return circuits are shared with the reference voltage circuit and signal return circuit used by the
electronic throttle body (ETB) throttle position sensor. The pedal position signal is converted 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.
3-Track APP Sensor
Typical 3-Track APP Sensor
There are 3 pedal position signals in the sensor. Signal 1, APP1, has a negative slope (increasing
angle, decreasing voltage) and signals 2 and 3, 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. 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. If a concern is present with one of the circuits
the other inputs are used. The pedal position signal is converted 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. There are 2 reference voltage circuits, 2 signal return circuits, and 3 signal
circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. The
reference voltage circuits and the signal return circuits are shared with the reference voltage circuit
and signal return circuit used by the electronic throttle body (ETB) throttle position sensor.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Locations
Air Flow Meter/Sensor: Locations
View 151-8
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Locations > Page 2945
View 151-9
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Locations > Page 2946
C1454
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Locations > Page 2947
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Locations > Page 2948
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Locations > Page 2949
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 sensor.
- To install, tighten to 2 Nm (18 lb-in).
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor >
Component Information > Locations
Intake Air Temperature Sensor: Locations
View 151-8
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor >
Component Information > Locations > Page 2953
View 151-9
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor >
Component Information > Locations > Page 2954
C1454
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor >
Component Information > Locations > Page 2955
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor >
Component Information > Locations > Page 2956
fuel, spark, and air flow.
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 above. 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.
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor >
Component Information > Locations > Page 2957
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component
Information > Locations
Brake Signal: Locations
View 151-1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component
Information > Locations > Page 2961
View 151-4
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component
Information > Locations > Page 2962
C278
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component
Information > Locations > Page 2963
Brake Signal: Description and Operation
Brake Pedal Position (BPP) Switch
Typical BPP Switch
The BPP switch is sometimes referred to as the 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 antilock 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.
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Locations > Camshaft Position Sensor 1
View 151-9
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Locations > Camshaft Position Sensor 1 > Page 2968
View 151-9
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Locations > Camshaft Position Sensor 1 > Page 2969
View 151-7
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Camshaft Position Sensor
C180
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Camshaft Position Sensor > Page 2972
C1366
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Camshaft Position Sensor > Page 2973
C1367
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Page 2974
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Page 2975
Camshaft Position Sensor: Service and Repair
CAMSHAFT POSITION (CMP) SENSOR
Removal and Installation
RH side
1. Remove the air cleaner (ACL) outlet pipe.
Both sides
2. Disconnect the camshaft position (CMP) sensor electrical connector. 3. Remove the bolt and the
CMP sensor.
- To install, tighten to 10 Nm (89 lb-in).
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Diagrams
C1064
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations
Crankshaft Position Sensor: Locations
View 151-8
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations > Page 2985
View 151-9
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations > Page 2986
Crankshaft Position Sensor: Diagrams
C101
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations > Page 2987
C1120
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations > Page 2988
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 decelerations between teeth.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations > Page 2989
Crankshaft Position Sensor: Service and Repair
CRANKSHAFT POSITION (CKP) SENSOR
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations > Page 2990
Removal and Installation
1. With vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt. 3.
Disconnect the A/C compressor coil electrical connector. 4. Detach the battery cable retainer from
the A/C compressor stud bolts. 5. Remove the nut and detach the A/C tube bracket.
- To install, tighten to 10 Nm (89 lb-in).
6. Remove the stud bolts and position the A/C compressor aside.
- To install, tighten to 25 Nm (18 lb-ft).
7. Disconnect the crankshaft position (CKP) sensor electrical connector. 8. Remove the bolt and
the CKP sensor.
- To install, tighten to 10 Nm (89 lb-in).
9. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 2996
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 2997
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 2998
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 2999
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3000
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3001
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3002
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3003
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3004
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3005
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3006
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3007
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3008
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 3009
C251
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator >
Component Information > Locations
Electronic Throttle Actuator: Locations
View 151-7
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator >
Component Information > Locations > Page 3013
View 151-9
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator >
Component Information > Locations > Page 3014
C1368
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator >
Component Information > Locations > Page 3015
Electronic Throttle Actuator: Description and Operation
ELECTRONIC THROTTLE ACTUATOR CONTROL (TAC)
Typical In-line TAC Design
Typical Parallel TAC Design
The electronic TAC is a DC motor controlled by the PCM (requires 2 wires). There are 2 designs
for the TAC, parallel and in-line. 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-line design has a
separate motor housing. An internal spring is used in both designs to return the throttle plate to a
default position. The default position is typically a throttle angle of 7 to 8 degrees from the hard stop
angle. The closed throttle plate hard stop is used to prevent the throttle from binding in the bore
(approximately 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 (V8-4.6L (2008))
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.
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
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: -
The throttle actuator control (TAC) motor is a DC motor controlled by the PCM (requires 2-wires).
- There are 2 designs: parallel and in-line. 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-line design has a
separate motor housing.
- An internal spring is used in both designs to return the throttle plate to a default position. The
default position is typically a throttle angle of 7 to 8 degrees from the hard stop angle.
- The closed throttle plate hard stop is used to prevent the throttle from binding in the bore
(approximately 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.
- 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.
- There is 1 reference voltage and 1 signal return circuit between the PCM and the ETB. The
reference voltage circuit and the signal return circuit is shared with the reference voltage circuits
and signal return circuits used by the APP sensor. There are also 2 TP signal circuits for
redundancy. The redundant TP 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). The TP2 signal reaches a limit of
approximately 4.5 volts at approximately 45 degrees of throttle angle.
Accelerator Pedal Position (APP) Sensor
Depending on the application either a 2-track or 3-track APP sensor is used.
Electronic Throttle Control (ETC) System Strategy
ETC System With A 3-Track APP Sensor Failure Mode And Effects Management (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module
> Component Information > Description and Operation > Page 3019
ETC System With A 3-Track APP Sensor Failure Mode And Effects Management (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module
> Component Information > Description and Operation > Page 3020
ETC System With A 2-Track APP Sensor Failure Mode And Effects Management
Electronic Throttle Monitor Operation
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module
> Component Information > Description and Operation > Page 3021
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 separate monitoring 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, appropriate corrective action is taken.
APP and TP Sensor Inputs
Accelerator Pedal Position (APP) Sensor Check
Throttle Position (TP) Sensor Check
Electronic Throttle Actuator Control (TAC) Output
Electronic TAC Operation Check
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 09-22-6 > Nov > 09
> Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle
Engine Control Module: Customer Interest Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow
Idle
TSB 09-22-6
11/16/09
4.6L ENGINE -CHECK ENGINE LIGHT ON - DTC P0196 - COLD WEATHER DRIVING
CONDITIONS- CALIBRATION UPDATE
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
ISSUE Some 2006-2008 Explorer, Mountaineer and Sport Trac vehicles and equipped with 4.6L
3-V engines may exhibit:
^ Diagnostic trouble code (DTC) P0196 - engine oil temperature (EOT) sensor range/performance
during ice/snow driving conditions.
^ Idle speed dropping below specification, hesitation or loss of RPM with no DTCs stored in the
Powertrain Control Module (PCM).
^ Cruise control surge at approximately 50-60 MPH (80-97 Km/h) in hilly regions Only applies to
vehicles operated in altitudes above 5000 feet (1.52
km).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
If normal Powertrain Controls/Emissions Diagnosis (PC/ED) diagnostics do not resolve the above
vehicle concerns, reprogram the PCM and Transmission Control Module (1CM) to the latest
calibration using IDS release 63.08 and higher. This new calibration is not included in the VCM
2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
VEHICLES EQUIPPED WITH A PCM AND TCM, REQUIRE A COORDINATED
REPROGRAMMING.
THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS
OUTLINED BY THE INTERGRATED DIAGNOSTIC SYSTEM (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 63.08 and higher. This new calibration
is not included in the VCM 2009.9 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:
(1) Choose all Tests and Calibrations.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 09-22-6 > Nov > 09
> Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle > Page 3030
(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
DISCONNECTING 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 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. Brake gently to a complete
stop and hold foot on brake for at least 10 seconds.
g. Repeat Steps (e-f) a total of three (3) 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
092206A 2006-2008 Explorer, 1.0 Hr.
Mountaineer 2007-2008 Explorer Sport Trac: Check DTCs, Reprogram The PCM And TCM
Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor
Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-22-6
> Nov > 09 > Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle
Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0196/RPM
Loss/Slow Idle
TSB 09-22-6
11/16/09
4.6L ENGINE -CHECK ENGINE LIGHT ON - DTC P0196 - COLD WEATHER DRIVING
CONDITIONS- CALIBRATION UPDATE
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
ISSUE Some 2006-2008 Explorer, Mountaineer and Sport Trac vehicles and equipped with 4.6L
3-V engines may exhibit:
^ Diagnostic trouble code (DTC) P0196 - engine oil temperature (EOT) sensor range/performance
during ice/snow driving conditions.
^ Idle speed dropping below specification, hesitation or loss of RPM with no DTCs stored in the
Powertrain Control Module (PCM).
^ Cruise control surge at approximately 50-60 MPH (80-97 Km/h) in hilly regions Only applies to
vehicles operated in altitudes above 5000 feet (1.52
km).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
If normal Powertrain Controls/Emissions Diagnosis (PC/ED) diagnostics do not resolve the above
vehicle concerns, reprogram the PCM and Transmission Control Module (1CM) to the latest
calibration using IDS release 63.08 and higher. This new calibration is not included in the VCM
2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
VEHICLES EQUIPPED WITH A PCM AND TCM, REQUIRE A COORDINATED
REPROGRAMMING.
THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS
OUTLINED BY THE INTERGRATED DIAGNOSTIC SYSTEM (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 63.08 and higher. This new calibration
is not included in the VCM 2009.9 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:
(1) Choose all Tests and Calibrations.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-22-6
> Nov > 09 > Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle > Page 3036
(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
DISCONNECTING 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 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. Brake gently to a complete
stop and hold foot on brake for at least 10 seconds.
g. Repeat Steps (e-f) a total of three (3) 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
092206A 2006-2008 Explorer, 1.0 Hr.
Mountaineer 2007-2008 Explorer Sport Trac: Check DTCs, Reprogram The PCM And TCM
Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor
Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Page 3037
Engine Control Module: Locations
View 151-1
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Component Information > Technical Service Bulletins > Page 3038
View 151-4
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Component Information > Technical Service Bulletins > Page 3039
View 151-8
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Component Information > Technical Service Bulletins > Page 3040
View 151-10
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3043
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3044
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3045
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3046
Symbols (Part 2)
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3047
Symbols (Part 3)
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3048
Symbols (Part 4)
Symbols (Part 5)
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3049
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3050
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3051
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
3 = Splice tape
4 = Harness tape
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3052
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3053
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3054
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.
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, barrel squeeze tool handles appropriate 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.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3055
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3056
Engine Control Module: Connector Views
C175B (Part 1)
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3057
C175B (Part 2)
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3058
C175E (Part 1)
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3059
C175E (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3060
C175E (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3061
C175T (Part 1)
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 3062
C175T (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Service and Repair > Procedures
Engine Control Module: Procedures
FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM)
Description
The EEPROM is contained in an integrated circuit 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 PI635 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.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Service and Repair > Procedures > Page 3065
Engine Control Module: Removal and Replacement
POWERTRAIN CONTROL MODULE (PCM)
A/C Tube Brackets
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Component Information > Service and Repair > Procedures > Page 3066
PCM
Removal
All vehicles
1. NOTE: 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 3. Disconnect the RH front wheel speed sensor electrical connector. Remove the nut(s)
and position the A/C tube bracket(s) 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
bracket(s) and install the nut(s). Connect the RH front wheel speed sensor electrical connector.
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Component Information > Service and Repair > Procedures > Page 3067
- 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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor >
Component Information > Locations
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor >
Component Information > Locations > Page 3071
C107
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor >
Component Information > Locations > Page 3072
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.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor >
Component Information > Locations > Page 3073
Engine Temperature Sensor: Service and Repair
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Removal and Installation
1. Disconnect the battery ground cable. 2. Remove the intake manifold. 3. Disconnect the cylinder
head temperature (CHT) sensor electrical connector. 4. Remove and discard the CHT sensor.
- To install, tighten to 26 Nm 19 lb-ft).
5. To install, reverse the removal procedure.
- Do not reuse the CHT sensor. Install a new sensor.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component
Information > Description and Operation
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.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component
Information > Description and Operation > Page 3077
Fuel Level Sensor: Service and Repair
FUEL LEVEL SENDER
Removal
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working
on or near any fuel-related component. Highly flammable mixtures are always present and may be
ignited. Failure to follow these instructions may result in serious personal injury.
1. Remove the fuel pump. 2. Remove the screw and the fuel level sender cover.
3. NOTE: Note the routing of the fuel level sender wire for installation.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component
Information > Description and Operation > Page 3078
Remove the heat shrink tube covering the fuel level sender wire electrical connector.
4. Disconnect the fuel level sender wire electrical connector.
5. NOTE: Note the routing of the fuel level sender ground wire for installation.
Disconnect the ground wire and remove the screw and lift up to remove the fuel level sender.
Installation
1. Route the fuel level sender ground wire along the fuel pump body.
2. Route the fuel level sender wire through the center of the fuel pump.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component
Information > Description and Operation > Page 3079
3. NOTE: Both fuel gauge sending wires must be routed behind the metal sending unit plate.
Hook the fuel level sender on the fuel pump and install and tighten the screw. Connect the fuel
level sender unit ground wire.
4. Slide the heat shrink tube onto the wire harness and connect the fuel level sender wire electrical
connector.
5. WARNING: Do not use an open flame to shrink the heat shrink tube. Use a heat gun only. Fuel
residue may be ignited if an open flame is
used. Failure to follow this instruction may result in serious personal injury.
Using a heat gun, shrink the heat shrink tube.
6. Install the fuel level sender cover and screw and tighten the screw. 7. Install the fuel pump.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor >
Component Information > Locations
Fuel Tank Pressure Sensor: Locations
View 151-20
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor >
Component Information > Locations > Page 3083
View 151-25
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor >
Component Information > Locations > Page 3084
C435
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor >
Component Information > Locations > Page 3085
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor >
Component Information > Locations > Page 3086
Fuel Tank Pressure Sensor: Service and Repair
FUEL TANK PRESSURE SENSOR
Removal and Installation
WARNING:
- When working on or near the evaporative emission (EVAP) system, disconnect the battery ground
cable from the battery. The EVAP system contains fuel vapor and condensed fuel vapor, so an
electrical spark may cause a fire or explosion. Failure to follow this instruction may result in serious
personal injury.
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious personal injury.
1. Remove the evaporative emission (EVAP) canister. 2. Remove the fuel tank shield from the fuel
tank.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor >
Component Information > Locations > Page 3087
3. Disconnect the fuel tank pressure (FTP) sensor electrical connector. 4. Disconnect the 3 FTP
sensor and tube assembly quick connect couplings from the fuel pump module and the vapor vent
valves. 5. Remove the FTP sensor and tube assembly. 6. To install, reverse the removal
procedure. 7. Leak test the EVAP system. 8. Carry out the evaporative emission repair verification
drive cycle.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
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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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
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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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
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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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
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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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
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Symbols (Part 2)
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Symbols (Part 3)
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Symbols (Part 4)
Symbols (Part 5)
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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 terminal by pulling each wire at the end of the connector.
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Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
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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
3 = Splice tape
4 = Harness tape
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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.
3. lnstall 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 seat wire splice.
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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.
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 6.35mm (1/4 in) 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.
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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.
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, barrel squeeze tool handles appropriate 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.
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The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
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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.
14-1
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14-4
Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, 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 Location Views. See: Locations/Component Locations
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Information Bus: Description and Operation
COMMUNICATIONS NETWORK
NOTE: The smart junction box (SJB) is also known as the generic electronic module (GEM).
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 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.
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Network Topology
MS-CAN Network Operation
The MS-CAN 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 control module (ACM)
- Instrument cluster (IC)
- Driver seat module (DSM) (if equipped)
- Rear entertainment module (RETM) (if equipped)
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- Heating ventilation air conditioning (HVAC) module (if equipped)
- Parking aid module (PAM) (if equipped)
- Satellite digital audio receiver system (SDARS) module (if equipped)
- Power running board (PRB) module (if equipped)
HS-CAN Network Operation
The HS-CAN communicates using bussed messages. The HS-CAN 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
- Transmission control module (TCM) (if equipped)
- Restraints control module (RCM)
- ABS module
- Instrument cluster (IC)
- Occupant classification system module (OCSM)
- 4X4 control module (if equipped)
Network Termination
The CAN 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 120 ohm 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.
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Information Bus: Initial Inspection and Diagnostic Overview
Inspection and Verification
INSPECTION AND VERIFICATION
1. Verify the customer concern. 2. Visually inspect 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 ABS module)
- 19 (30A) (no communication with power running board [PRB] module)
- 23 (20A) (no communication with 4X4 control module)
- 24 (10A) (no communication with PCM)
- 26 (20A) (no communication with 4X4 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 digital audio receiver system [SDARS] module, rear
entertainment module [RETM])
- 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 control module [ACM])
- 4 (20A) (no power to scan tool)
- 8 (15A) (no communication with instrument cluster [IC])
- 9 (2A) (no communication with TCM, PCM)
- 12 (5A) (no communication with ACM)
- 17 (10A) (no communication with restraints control module [RCM], occupant classification system
module [OCSM])
- 18 (10A) (no communication with ABS module, 4X4 control module, parking aid module [PAM])
- 20 (10A) (no communication with heating ventilation air conditioning [HVAC]) module
- 24 (10A) (no communication with IC)
- 28 (10A) (no communication with HVAC module)
- Data link connector (DLC)
- Wiring harness
- Wiring, terminals or connectors
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 T, to diagnose No Power To The Scan Tool. See: Pinpoint Tests/Test T: 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 DTC Charts. 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
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Principles of Operation
PRINCIPLES OF OPERATION
NOTE: The smart junction box (SJB) is also known as the generic electronic module (GEM).
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 will not communicate while certain faults are present, but will operate with diminished
performance with other faults present. The MS-CAN may remain operational when 1 of the 2
termination resistors are not present.
The MS-CAN 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: Audio control module (ACM)
- Instrument cluster (IC)
- Smart junction box (SJB)
- Parking aid module (PAM) (if equipped)
- Driver seat module (DSM) (if equipped)
- Satellite digital audio receiver system (SDARS) module (if equipped)
- Power running board (PRB) module (if equipped)
- Rear entertainment module (RETM) (if equipped)
- Heating ventilation air conditioning (HVAC) module (if equipped)
The following fault chart describes the specific MS-CAN failures and their resulting symptom:
MS-CAN Communication Fault Chart
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
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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 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 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.
The following modules are on the HS-CAN: Instrument cluster (IC)
- PCM
- ABS module
- Restraints control module (RCM)
- Occupant classification system module (OCSM)
- Transmission control module (TCM) (if equipped)
- 4X4 control module (if equipped)
The following fault chart describes the specific HS-CAN failures and their resulting symptom:
HS-CAN Communication Fault Chart
The following chart describes the specific CAN messages broadcast by each module, and the
module(s) that receive the message:
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CAN Module Communication Message Chart (Part 1)
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CAN Module Communication Message Chart (Part 2)
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CAN Module Communication Message Chart (Part 3)
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CAN Module Communication Message Chart (Part 4)
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CAN Module Communication Message Chart (Part 5)
Inspection and Verification
INSPECTION AND VERIFICATION
This provides step-by-step module configuration procedures. Carry out the programmable module
installation (PMI) procedure when another Vehicle System directs to carry out configuration or
when DTCs from the given list are present. See: Programming and Relearning
Principles of Operation
PRINCIPLES OF OPERATION
NOTE: The smart junction box (SJB) is also known as the generic electronic module (GEM).
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 may be incorrect.
- P0602, P0605 and/or P1639 - sets when the 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
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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. See: Programming and Relearning
To carry out PMI, refer to Programmable Module Installation. See: Programming and Relearning
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.
The following chart lists body/chassis module As-Built data addresses:
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Body/Chassis Module Addresses for As-Built Entry
The following chart describes specific module programming information:
Module Configuration and Parameter Chart (Part 1)
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Module Configuration and Parameter Chart (Part 2)
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Information Bus: Diagnostic Trouble Code Descriptions
U0073-U0155
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U0159-U1900
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U1900-U2023
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U2471-U2511
B2477-B2900 / P0602-P1639 / U0300
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U2050-U2051
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Information Bus: Symptom Related Diagnostic Procedures
Symptom Chart (Part 1)
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Symptom Chart (Part 2)
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Symptom Chart (Part 3)
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Information Bus: Pinpoint Tests
Test A: The PCM Does Not Respond To The Scan Tool
PINPOINT TEST A: THE PCM DOES NOT RESPOND TO THE SCAN TOOL
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 with the transmission control
module (TCM) (if equipped), the ABS module, the restraints control module (RCM), the 4X4 control
module (if equipped), the occupant classification system module (OCSM) and the instrument
cluster (IC).
This pinpoint test is intended to diagnose the following:
- Wiring, terminals or connectors
- PCM
A1-A2
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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
Normal Operation
The 6R60 transmission utilizes a transmission control module (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 with the PCM, the ABS module,
the restraints control module (RCM), the 4X4 control module (if equipped), the occupant
classification system module (OCSM) and the instrument cluster (IC). Voltage for the TCM is
provided by circuits SBB27 (BU/RD) and CE517 (BU/GN). Circuit GD113 (BK/YE) provides ground.
This pinpoint test is intended to diagnose the following:
- Fuse
- Wiring, terminals or connectors
- TCM
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Test C: The ABS Module Does Not Respond To The Scan Tool
PINPOINT TEST C: THE ABS MODULE DOES NOT RESPOND TO THE SCAN TOOL
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 with the PCM, the
transmission control module (TCM) (if equipped), the restraints control module (RCM), the 4X4
control module (if equipped), the occupant classification system module (OCSM) and the
instrument cluster (IC). 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).
This pinpoint test is intended to diagnose the following:
- Fuse
- Wiring, terminals or connectors
- ABS module
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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
Normal Operation
The restraints control module (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 with the
PCM, the transmission control module (TCM) (if equipped), the ABS module, the 4X4 control
module (if equipped), the occupant classification system module (OCSM) and the instrument
cluster (IC). Voltage for the RCM is provided by circuit CBP17 (BN/GN), and the RCM is case
grounded.
This pinpoint test is intended to diagnose the following:
- Fuse
- Wiring, terminals or connectors
- RCM
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Test E: The 4X4 Control Module Does Not Respond To The Scan Tool
PINPOINT TEST E: THE 4X4 CONTROL MODULE DOES NOT RESPOND TO THE SCAN TOOL
Normal Operation
The 4X4 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 4X4 control module. The 4X4 control module shares the HS-CAN
with PCM, the transmission control module (TCM) (if equipped), the ABS module, the restraints
control module (RCM), the occupant classification system module (OCSM) and the instrument
cluster (IC). 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).
This pinpoint test is intended to diagnose the following:
- Fuse
- Wiring, terminals or connectors
- 4X4 control module
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Test F: The Occupant Classification System Module (OCSM) Does Not Respond To The Scan Tool
PINPOINT TEST F: THE OCCUPANT CLASSIFICATION SYSTEM MODULE (OCSM) DOES NOT
RESPOND TO THE SCAN TOOL
Normal Operation
The occupant classification system module (OCSM) 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 OCSM. The OCSM shares the HS-CAN
with the PCM, the transmission control module (TCM) (if equipped), the ABS module, the restraints
control module (RCM), the 4X4 control module (if equipped) and the instrument cluster (IC).
Voltage to the OCSM is supplied by circuit CBP17 (BN/GN). Ground is supplied by circuit GD145
(BK/BU).
This pinpoint test is intended to diagnose the following:
- Fuse
- Wiring, terminals or connectors
- OCSM
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Test G: The Instrument Cluster (IC) Does Not Respond To The Scan Tool
PINPOINT TEST G: THE INSTRUMENT CLUSTER (IC) DOES NOT RESPOND TO THE SCAN
TOOL
Normal Operation
The instrument cluster (IC) 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 connection to the IC and circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG)
(MS-CAN -) provide the MS-CAN connection to the IC. The IC shares the HS-CAN with the PCM,
the transmission control module (TCM) (if equipped), the ABS module, the restraints control
module (RCM), the 4X4 control module (if equipped) and the occupant classification system
module (OCSM). The IC shares the MS-CAN with the smart junction box (SJB), the heating
ventilation air conditioning (HVAC) module (if equipped), the audio control module (ACM), the
satellite digital audio receiver system (SDARS) module (if equipped), the driver seat module (DSM)
(if equipped), the parking aid module (PAM) (if equipped), the PRB module (if equipped) and the
rear entertainment module (RETM) (if equipped). Voltage for the IC is provided by circuits CDC34
(WH/OG) and SBP24 (VT/RD). Circuit GD145 (BK/BU) provides ground.
This pinpoint test is intended to diagnose the following:
- Fuse
- Wiring, terminals or connectors
- IC
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G5
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
Normal Operation
The smart junction box (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 with the IC,
the heating ventilation air conditioning (HVAC) module (if equipped), the audio control module
(ACM), the satellite digital audio receiver system (SDARS) module (if equipped), the driver seat
module (DSM) (if equipped), the parking aid module (PAM) (if equipped), the power running board
(PRB) module (if equipped), and the rear entertainment module (RETM) (if equipped). Voltage for
the SJB is provided by circuit SBB03 (BU/RD). Circuit GD108 (BK/VT) provides ground.
This pinpoint test is intended to diagnose the following:
- Fuse
- Wiring, terminals or connectors
- SJB
H1
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Test I: The Heating Ventilation Air Conditioning (HVAC) Module Does Not Respond To The Scan
Tool
PINPOINT TEST I: THE HEATING VENTILATION AIR CONDITIONING (HVAC) MODULE DOES
NOT RESPOND TO THE SCAN TOOL
Normal Operation
The heating ventilation air conditioning (HVAC) 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 HVAC module. The HVAC
module shares the MS-CAN with the instrument cluster (IC), the smart junction box (SJB), the
audio control module (ACM), the satellite digital audio receiver system (SDARS) module (if
equipped), the rear entertainment module (RETM) (if equipped), the driver seat module (DSM) (if
equipped), the power running board (PRB) module (if equipped) and the parking aid module (PAM)
(if equipped). Voltage for the HVAC module is provided by circuits CBP20 (YE/VT) and SBP28
(GN/RD). Circuit GD145 (BK/BU) provides ground.
This pinpoint test is intended to diagnose the following:
- Fuse
- Wiring, terminals or connectors
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- HVAC module
I1-I2
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Test J: The Audio Control Module (ACM) Does Not Respond To The Scan Tool
PINPOINT TEST J: THE AUDIO CONTROL MODULE (ACM) DOES NOT RESPOND TO THE
SCAN TOOL
Normal Operation
Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network
connection to the audio control module (ACM). The ACM shares the MS-CAN with the instrument
cluster (IC), the smart junction box (SJB), the heating ventilation air conditioning (HVAC) module (if
equipped), the satellite digital audio receiver system (SDARS) module (if equipped), the rear
entertainment module (RETM), the driver seat module (DSM) (if equipped), the power running
board (PRB) module (if equipped) and the parking aid module (PAM) (if equipped). Voltage for the
ACM is provided by circuits CBP12 (GN/WH) and SBP03 (BU/RD). Circuit GD114 (BK/BU)
provides ground.
This pinpoint test is intended to diagnose the following:
- Fuse
- Wiring, terminals or connectors
- ACM
J1
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Test K: The Satellite Digital Audio Receiver System (SDARS) Module Does Not Respond To The
Scan Tool
PINPOINT TEST K: THE SATELLITE DIGITAL AUDIO RECEIVER SYSTEM (SDARS) MODULE
DOES NOT RESPOND TO THE SCAN TOOL
Normal Operation
The satellite digital audio receiver system (SDARS) 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 SDARS module. The
SDARS module shares the MS-CAN with the instrument cluster (IC), the smart junction box (SJB),
the heating ventilation air conditioning (HVAC) module (if equipped), the audio control module
(ACM), the rear entertainment module (RETM) (if equipped), the driver seat module (DSM) (if
equipped), the power running board (PRB) module (if equipped), and the parking aid module
(PAM) (if equipped). Voltage for the SDARS module is provided by circuit SBB41 (RD). Circuit
GD114 (BK/BU) provides ground.
This pinpoint test is intended to diagnose the following:
- Fuse
- Wiring, terminals or connectors
- SDARS module
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Test L: The Rear Entertainment Module (RETM) Does Not Respond To The Scan Tool
PINPOINT TEST L: THE REAR ENTERTAINMENT MODULE (RETM) DOES NOT RESPOND TO
THE SCAN TOOL
Normal Operation
The rear entertainment module (RETM) 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 RETM. The RETM is only on vehicles
equipped with rear seat entertainment. The RETM shares the MS-CAN with the instrument cluster
(IC), the smart junction box (SJB), the heating ventilation air conditioning (HVAC) module (if
equipped), the audio control module (ACM), the satellite digital audio receiver system (SDARS)
module (if equipped), the driver seat module (DSM) (if equipped), the RETM (if equipped), the
power running board (PRB) module (if equipped), and the parking aid module (PAM) (if equipped).
Voltage for the RETM is provided by circuit SBB41 (RD). Circuit GD114 (BK/BU) provides ground.
This pinpoint test is intended to diagnose the following:
- Fuse
- Wiring, terminals or connectors
- RETM
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Test M: The Driver Seat Module (DSM) Does Not Respond To The Scan Tool
PINPOINT TEST M: THE DRIVER SEAT MODULE (DSM) DOES NOT RESPOND TO THE SCAN
TOOL
Normal Operation
The driver seat module (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 with the
instrument cluster (IC), the smart junction box (SJB), the heating ventilation air conditioning
(HVAC) module (if equipped), the audio control module (ACM), the rear entertainment module
(RETM) (if equipped), the satellite digital audio receiver system (SDARS) module (if equipped), the
power running board (PRB) module (if equipped) and the parking aid module (PAM) (if equipped).
Voltage for the DSM is provided by circuit SBP01 (RD). Circuit GD143 (BK/OG) provides ground.
This pinpoint test is intended to diagnose the following:
- Fuse
- Wiring, terminals or connectors
- DSM
M1
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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
Normal Operation
The power running board (PRB) 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 PRB module. The PRB module shares
the MS-CAN with the instrument cluster (IC), the smart junction box (SJB), the heating ventilation
air conditioning (HVAC) module (if equipped), the audio control module (ACM), the rear
entertainment module (RETM) (if equipped), the driver seat module (DSM) (if equipped), the
satellite digital audio receiver system (SDARS) module (if equipped), and the parking aid module
(PAM) (if equipped). Voltage for the PRB module is provided by circuit SBB19 (BU/RD). Circuit
GD151 (BK/GN) provides ground.
This pinpoint test is intended to diagnose the following:
- Fuse
- Wiring, terminals or connectors
- PRB module
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Test O: The Parking Aid Module Does Not Respond To The Scan Tool
PINPOINT TEST O: THE PARKING AID MODULE DOES NOT RESPOND TO THE SCAN TOOL
Normal Operation
The parking aid module (PAM) 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 PAM. The PAM shares the MS-CAN with the
instrument cluster (IC), the smart junction box (SJB), the heating ventilation air conditioning
(HVAC) module (if equipped), the audio control module (ACM), the rear entertainment module
(RETM) (if equipped), the satellite digital audio receiver system (SDARS) module (if equipped), and
the power running board (PRB) module (if equipped). Voltage for the PAM is provided by circuit
CBP18 (GY/OG). Circuit GD145 (BK/BU) provides ground.
This pinpoint test is intended to diagnose the following:
- Fuse
- Wiring, terminals or connectors
- PAM
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O7-O8
Test P: No Medium Speed Controller Area Network (MS-CAN) Communication, All Modules Are
Not Responding
PINPOINT TEST P: NO MEDIUM SPEED CONTROLLER AREA NETWORK (MS-CAN)
COMMUNICATION, ALL MODULES ARE NOT RESPONDING
Normal Operation
The medium speed controller area network (MS-CAN) 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 (IC), the heating ventilation air
conditioning (HVAC) module (if equipped), the audio control module (ACM), the satellite digital
audio receiver system (SDARS) module (if equipped), the rear entertainment module (RETM) (if
equipped), the power running board (PRB) module (if equipped), the parking aid module (PAM) (if
equipped), and the driver seat module (DSM) all communicate with the scan tool using the
MS-CAN.
This pinpoint test is intended to diagnose the following:
- Wiring, terminals or connectors
- SJB
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3172
- IC
- ACM
- HVAC module (if equipped)
- RETM (if equipped)
- DSM (if equipped)
- SDARS module (if equipped)
- PRB module (if equipped)
- PAM (if equipped)
P1-P2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3173
P2-P4
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3174
P5-P7
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3175
P7-P8
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3176
P9-P12
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3177
P12-P16
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3178
P16-P20
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3179
P20-P23
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3180
P23-P25
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3181
P25-P29
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3182
P29-P33
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3183
P33-P36
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3184
P37-P40
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3185
P41-P44
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3186
P45-P46
Test Q: Intermittent No Medium Speed Controller Area Network (MS-CAN) Communication, One
Or More Modules Are Not Responding Dur
PINPOINT TEST Q: INTERMITTENT NO MEDIUM SPEED CONTROLLER AREA NETWORK
(MS-CAN) COMMUNICATION, ONE OR MORE MODULES ARE NOT RESPONDING DURING
NETWORK TEST
Normal Operation
An open circuit VDB06 (GY/OG) (MS-CAN +) or VDB07 (VT/OG) (MS-CAN -) may cause
intermittent or unreliable communication to all modules on the high speed controller area network
(HS-CAN). The HS-CAN is used for communication between the following modules:
- Audio control module (ACM)
- Rear entertainment module (RETM)
- Driver seat module (DSM)
- Heating ventilation air conditioning (HVAC) module
- Instrument cluster (IC)
- Parking aid module (PAM)
- Power running board (PRB) module
- Satellite digital audio receiver system (SDARS) module
- Smart junction box (SJB)
In the event that one of the 2 network circuits (MS-CAN + or MS-CAN -) becomes open to a
module on the network, unreliable network communication to all modules on the network may
result.
This pinpoint test is intended to diagnose the following:
- Wiring, terminals or connectors.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3187
Q1
Q1-Q2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3188
Q3-Q6
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3189
Q7-Q13
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3190
Q14-Q16
Test R: No High Speed Controller Area Network (HS-CAN) Communication, All Modules Are Not
Responding
PINPOINT TEST R: NO HIGH SPEED CONTROLLER AREA NETWORK (HS-CAN)
COMMUNICATION, ALL MODULES ARE NOT RESPONDING
Normal Operation
The high speed controller area network (HS-CAN) uses an unshielded twisted pair cable, circuits
VDB04 (WH/BU) and VDB05 (WH). The PCM, the transmission control module (TCM), the ABS
module, the restraints control module (RCM), the 4X4 control module (if equipped), the occupant
classification system module (OCSM) and the instrument cluster (IC) all communicate with the
scan tool using the HS-CAN.
This pinpoint test is intended to diagnose the following:
- Wiring, terminals or connectors
- PCM
- RCM
- ABS module
- IC
- TCM (if equipped)
- 4X4 control module (if equipped)
- OCSM
R1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3191
R1-R2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3192
R3-R4
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3193
R5-R6
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3194
R7-R8
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3195
R8-R10
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3196
R10-R11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3197
R12-R16
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3198
R16-R18
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3199
R18-R20
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3200
R20-R23
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3201
R23-R26
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3202
R26-R28
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3203
R28-R30
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3204
R31-R34
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3205
R35
Test S: Intermittent No High Speed Controller Area Network (HS-CAN) Communication, One Or
More Modules Are Not Responding Durin
PINPOINT TEST S: INTERMITTENT NO HIGH SPEED CONTROLLER AREA NETWORK
(HS-CAN) COMMUNICATION, ONE OR MORE MODULES ARE NOT RESPONDING DURING
NETWORK TEST
Normal Operation
An open circuit VDB04 (WH/BU) (HS-CAN +) or VDB05 (WH) (HS-CAN -) may cause intermittent
or unreliable communication to all modules on the HS-CAN. The HS-CAN is used for
communication between the following modules: ABS module
- Instrument cluster (IC)
- Occupant classification system module (OCSM)
- PCM
- Restraints control module (RCM)
- Transmission control module (TCM) (6R60 transmission only)
- 4X4 control module (if equipped)
In the event that one of the 2 network circuits (HS-CAN + or HS-CAN -) becomes open to a module
on the network, unreliable network communication to all modules on the network may result.
This pinpoint test is intended to diagnose the following:
- Wiring, terminals or connectors
S1
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3206
S1-S2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3207
S3-S5
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3208
S6-S11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3209
S12
Test T: No Power To The Scan Tool
PINPOINT TEST T: NO POWER TO THE SCAN TOOL
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).
This pinpoint test is intended to diagnose the following:
- Fuse
- Wiring, terminals or connectors
- Scan tool
T1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3210
T2-T3
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3211
Information Bus: Programming and Relearning
Programmable Module Installation (PMI)
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.
Accessory Protocol Interface Module (APIM) Programming
Accessory Protocol Interface Module (APIM) Programming
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3212
Accessory Protocol Interface Module (APIM) Programming Using the Integrated Diagnostic System
(IDS)
NOTE: If a new Accessory Protocol Interface Module (APIM) is being installed, install the new
APIM before carrying out the following procedure.
1. Turn the Audio Control Module (ACM) on.
2. Connect the scan tool to the Data Link Connector (DLC).
3. Connect one end of the Universal Serial Bus (USB) male-A to male-A cable to the scan tool.
4. Connect the other end of the USB male-A to male-A cable to the vehicle USB port.
5. From the technician service publication website, run On-Line Automotive Service Information
System (OASIS) using Quick Start or by manually
entering the Vehicle Identification Number (VIN).
6. From the OASIS tab, select the "Sync/APIM" bullet.
7. Select the "Read APIM" button to verify the current APIM Vehicle Interface Processor (VIP) and
Consumer Interface Processor (CIP) software
levels.
8. NOTE: Do not disconnect the Vehicle Communication Module (VCM) or USB cables during
APIM programming.
Select the desired software level from the list of available software for programming then select the
"Program APIM" button to begin the APIM programming process. Enter the APIM As-Built data if
prompted.
- When the VIP is programmed, the CIP will be programmed automatically.
9. The Sync/APIM application downloads the software into the APIM and displays "Programming
has been completed successfully".
10. Test the audio system for correct operation.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Page 3213
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Tools and Equipment > Module Communications Network > Page 3216
Special Tool(s)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Locations
View 151-8
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Locations > Page 3220
C108
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Locations > Page 3221
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Locations > Page 3225
Main Relay (Computer/Fuel System): Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Temperature Sensor For ECM
> Component Information > Locations
View 151-10
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Temperature Sensor For ECM
> Component Information > Locations > Page 3235
C104
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Temperature Sensor For ECM
> Component Information > Locations > Page 3236
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Temperature Sensor For ECM
> Component Information > Locations > Page 3237
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Heated Oxygen Sensor (HO2S) #11
Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #11
View 151-10
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3242
View 151-11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3243
View 151-11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3244
Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #21
View 151-7
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3245
View 151-11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3246
View 151-12
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3247
Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #22
View 151-7
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3248
View 151-11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 3249
View 151-12
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 3252
C142
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 3253
C171
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 3254
C172
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Page 3255
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.
Universal HO2S
The universal HO2S, sometimes referred to as a wideband oxygen sensor, uses the typical HO2S
combined with a current controller in the PCM to infer an air/fuel ratio relative to the stoichiometric
air/fuel ratio. This is accomplished by balancing the amount of oxygen ions pumped in or out of a
measurement chamber within the sensor. The typical HO2S within the universal HO2S is used to
detect the oxygen content of the exhaust gas in the measurement chamber. The oxygen content
inside the measurement chamber is maintained at the stoichiometric air/fuel ratio by pumping
oxygen ions in and out of the measurement chamber. As the exhaust gasses get richer or leaner,
the amount of oxygen that must be pumped in or out to maintain a stoichiometric air/fuel ratio in the
measurement chamber varies in proportion to the air/fuel ratio. The amount of current required to
pump the oxygen ions in or out of the measurement chamber is used to measure the air/fuel ratio.
The measured air/fuel ratio is actually the output from the current controller in the PCM and not a
signal that comes directly from the sensor.
The universal HO2S also uses a self-contained reference chamber to make sure an oxygen
differential is always present. The oxygen for the reference chamber is supplied by pumping small
amounts of oxygen ions from the measurement chamber into the reference chamber. The universal
HO2S does not need access to outside air.
Part to part variance is compensated for by placing a resistor in the connector. This resistor is used
to trim the current measured by the current controller in the PCM.
Embedded with the sensing element is the universal H02S heater. The heater allows the engine to
enter closed loop operation sooner. The heating element heats the sensor to a temperature of
780°C (1,436°F). The VPWR circuit supplies voltage to the heater. The PCM controls the heater on
and off by providing the ground to maintain the sensor at the correct temperature for maximum
accuracy.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3258
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3259
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3260
Oxygen Sensor: Service and Repair Catalyst Monitor Sensor
CATALYST MONITOR SENSOR
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3261
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 3262
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch >
Component Information > Locations
View 151-2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch >
Component Information > Locations > Page 3266
C121
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch >
Component Information > Locations > Page 3267
Power Steering Pressure Switch: Description and Operation
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.
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Description and Operation > Page 3271
The tube mounted differential pressure feedback EGR sensor is identical in operation as the larger
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 (V8-4.6L (2008))
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.
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
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: -
The throttle actuator control (TAC) motor is a DC motor controlled by the PCM (requires 2-wires).
- There are 2 designs: parallel and in-line. 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-line design has a
separate motor housing.
- An internal spring is used in both designs to return the throttle plate to a default position. The
default position is typically a throttle angle of 7 to 8 degrees from the hard stop angle.
- The closed throttle plate hard stop is used to prevent the throttle from binding in the bore
(approximately 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.
- 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.
- There is 1 reference voltage and 1 signal return circuit between the PCM and the ETB. The
reference voltage circuit and the signal return circuit is shared with the reference voltage circuits
and signal return circuits used by the APP sensor. There are also 2 TP signal circuits for
redundancy. The redundant TP 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). The TP2 signal reaches a limit of
approximately 4.5 volts at approximately 45 degrees of throttle angle.
Accelerator Pedal Position (APP) Sensor
Depending on the application either a 2-track or 3-track APP sensor is used.
Electronic Throttle Control (ETC) System Strategy
ETC System With A 3-Track APP Sensor Failure Mode And Effects Management (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
3276
ETC System With A 3-Track APP Sensor Failure Mode And Effects Management (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
3277
ETC System With A 2-Track APP Sensor Failure Mode And Effects Management
Electronic Throttle Monitor Operation
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
3278
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 separate monitoring 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, appropriate corrective action is taken.
APP and TP Sensor Inputs
Accelerator Pedal Position (APP) Sensor Check
Throttle Position (TP) Sensor Check
Electronic Throttle Actuator Control (TAC) Output
Electronic TAC Operation Check
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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: > 09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle
Engine Control Module: Customer Interest Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow
Idle
TSB 09-22-6
11/16/09
4.6L ENGINE -CHECK ENGINE LIGHT ON - DTC P0196 - COLD WEATHER DRIVING
CONDITIONS- CALIBRATION UPDATE
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
ISSUE Some 2006-2008 Explorer, Mountaineer and Sport Trac vehicles and equipped with 4.6L
3-V engines may exhibit:
^ Diagnostic trouble code (DTC) P0196 - engine oil temperature (EOT) sensor range/performance
during ice/snow driving conditions.
^ Idle speed dropping below specification, hesitation or loss of RPM with no DTCs stored in the
Powertrain Control Module (PCM).
^ Cruise control surge at approximately 50-60 MPH (80-97 Km/h) in hilly regions Only applies to
vehicles operated in altitudes above 5000 feet (1.52
km).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
If normal Powertrain Controls/Emissions Diagnosis (PC/ED) diagnostics do not resolve the above
vehicle concerns, reprogram the PCM and Transmission Control Module (1CM) to the latest
calibration using IDS release 63.08 and higher. This new calibration is not included in the VCM
2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
VEHICLES EQUIPPED WITH A PCM AND TCM, REQUIRE A COORDINATED
REPROGRAMMING.
THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS
OUTLINED BY THE INTERGRATED DIAGNOSTIC SYSTEM (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 63.08 and higher. This new calibration
is not included in the VCM 2009.9 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:
(1) Choose all Tests and Calibrations.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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: > 09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle > Page
3287
(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
DISCONNECTING 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 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. Brake gently to a complete
stop and hold foot on brake for at least 10 seconds.
g. Repeat Steps (e-f) a total of three (3) 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
092206A 2006-2008 Explorer, 1.0 Hr.
Mountaineer 2007-2008 Explorer Sport Trac: Check DTCs, Reprogram The PCM And TCM
Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor
Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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: > 09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow
Idle
Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0196/RPM
Loss/Slow Idle
TSB 09-22-6
11/16/09
4.6L ENGINE -CHECK ENGINE LIGHT ON - DTC P0196 - COLD WEATHER DRIVING
CONDITIONS- CALIBRATION UPDATE
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
ISSUE Some 2006-2008 Explorer, Mountaineer and Sport Trac vehicles and equipped with 4.6L
3-V engines may exhibit:
^ Diagnostic trouble code (DTC) P0196 - engine oil temperature (EOT) sensor range/performance
during ice/snow driving conditions.
^ Idle speed dropping below specification, hesitation or loss of RPM with no DTCs stored in the
Powertrain Control Module (PCM).
^ Cruise control surge at approximately 50-60 MPH (80-97 Km/h) in hilly regions Only applies to
vehicles operated in altitudes above 5000 feet (1.52
km).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
If normal Powertrain Controls/Emissions Diagnosis (PC/ED) diagnostics do not resolve the above
vehicle concerns, reprogram the PCM and Transmission Control Module (1CM) to the latest
calibration using IDS release 63.08 and higher. This new calibration is not included in the VCM
2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
VEHICLES EQUIPPED WITH A PCM AND TCM, REQUIRE A COORDINATED
REPROGRAMMING.
THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS
OUTLINED BY THE INTERGRATED DIAGNOSTIC SYSTEM (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 63.08 and higher. This new calibration
is not included in the VCM 2009.9 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:
(1) Choose all Tests and Calibrations.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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: > 09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow
Idle > Page 3293
(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
DISCONNECTING 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 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. Brake gently to a complete
stop and hold foot on brake for at least 10 seconds.
g. Repeat Steps (e-f) a total of three (3) 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
092206A 2006-2008 Explorer, 1.0 Hr.
Mountaineer 2007-2008 Explorer Sport Trac: Check DTCs, Reprogram The PCM And TCM
Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor
Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3294
Engine Control Module: Locations
View 151-1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3295
View 151-4
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3296
View 151-8
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3297
View 151-10
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
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and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3300
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
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and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3301
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
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Instructions > Page 3302
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
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and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3303
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3304
Symbols (Part 3)
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and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3305
Symbols (Part 4)
Symbols (Part 5)
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and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3306
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 terminal by pulling each wire at the end of the connector.
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and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3307
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
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and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3308
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
3 = Splice tape
4 = Harness tape
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Instructions > Page 3309
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.
3. lnstall 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 seat wire splice.
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and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3310
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.
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 6.35mm (1/4 in) 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.
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and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3311
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.
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, barrel squeeze tool handles appropriate 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.
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and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3312
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
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and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3313
Engine Control Module: Connector Views
C175B (Part 1)
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and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3314
C175B (Part 2)
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and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3315
C175E (Part 1)
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and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3316
C175E (Part 2)
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and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3317
C175E (Part 3)
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and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3318
C175T (Part 1)
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and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3319
C175T (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures
Engine Control Module: Procedures
FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM)
Description
The EEPROM is contained in an integrated circuit 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 PI635 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.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3322
Engine Control Module: Removal and Replacement
POWERTRAIN CONTROL MODULE (PCM)
A/C Tube Brackets
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and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3323
PCM
Removal
All vehicles
1. NOTE: 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 3. Disconnect the RH front wheel speed sensor electrical connector. Remove the nut(s)
and position the A/C tube bracket(s) 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
bracket(s) and install the nut(s). Connect the RH front wheel speed sensor electrical connector.
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and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3324
- 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.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
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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 3328
Main Relay (Computer/Fuel System): Testing and Inspection
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View 151-13
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C2040
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3334
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
amount of torque requested by the operator. Depending on the application either a 2-track or
3-track APP sensor is used.
2-Track APP Sensor
2-Track APP Sensor
There are 2 pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive
slope (increasing angle, increasing voltage), but are offset and increase at different rates. The 2
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. If a concern is present with one of the circuits the other input is used. There are 2
reference voltage circuits, 2 signal return circuits, and 2 signal circuits (a total of 6 circuits and pins)
between the PCM and the APP sensor assembly. The reference voltage circuits and the signal
return circuits are shared with the reference voltage circuit and signal return circuit used by the
electronic throttle body (ETB) throttle position sensor. The pedal position signal is converted 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.
3-Track APP Sensor
Typical 3-Track APP Sensor
There are 3 pedal position signals in the sensor. Signal 1, APP1, has a negative slope (increasing
angle, decreasing voltage) and signals 2 and 3, 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. 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. If a concern is present with one of the circuits
the other inputs are used. The pedal position signal is converted 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. There are 2 reference voltage circuits, 2 signal return circuits, and 3 signal
circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. The
reference voltage circuits and the signal return circuits are shared with the reference voltage circuit
and signal return circuit used by the electronic throttle body (ETB) throttle position sensor.
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Air Flow Meter/Sensor: Locations
View 151-8
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C1454
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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
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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.
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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 sensor.
- To install, tighten to 2 Nm (18 lb-in).
3. To install, reverse the removal procedure.
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Sensor 1
View 151-9
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Sensor 1 > Page 3347
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Sensor 1 > Page 3348
View 151-7
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Sensor
C180
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Sensor > Page 3351
C1366
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Sensor > Page 3352
C1367
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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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3354
Camshaft Position Sensor: Service and Repair
CAMSHAFT POSITION (CMP) SENSOR
Removal and Installation
RH side
1. Remove the air cleaner (ACL) outlet pipe.
Both sides
2. Disconnect the camshaft position (CMP) sensor electrical connector. 3. Remove the bolt and the
CMP sensor.
- To install, tighten to 10 Nm (89 lb-in).
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Diagrams
C1064
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations
Crankshaft Position Sensor: Locations
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Crankshaft Position Sensor: Diagrams
C101
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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 decelerations between teeth.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Crankshaft Position Sensor: Service and Repair
CRANKSHAFT POSITION (CKP) SENSOR
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Removal and Installation
1. With vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt. 3.
Disconnect the A/C compressor coil electrical connector. 4. Detach the battery cable retainer from
the A/C compressor stud bolts. 5. Remove the nut and detach the A/C tube bracket.
- To install, tighten to 10 Nm (89 lb-in).
6. Remove the stud bolts and position the A/C compressor aside.
- To install, tighten to 25 Nm (18 lb-ft).
7. Disconnect the crankshaft position (CKP) sensor electrical connector. 8. Remove the bolt and
the CKP sensor.
- To install, tighten to 10 Nm (89 lb-in).
9. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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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 (V8-4.6L (2008))
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Engine Temperature Sensor: Service and Repair
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Removal and Installation
1. Disconnect the battery ground cable. 2. Remove the intake manifold. 3. Disconnect the cylinder
head temperature (CHT) sensor electrical connector. 4. Remove and discard the CHT sensor.
- To install, tighten to 26 Nm 19 lb-ft).
5. To install, reverse the removal procedure.
- Do not reuse the CHT sensor. Install a new sensor.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation
Fuel Level Sensor: Description and Operation
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 (V8-4.6L (2008))
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Fuel Level Sensor: Service and Repair
FUEL LEVEL SENDER
Removal
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working
on or near any fuel-related component. Highly flammable mixtures are always present and may be
ignited. Failure to follow these instructions may result in serious personal injury.
1. Remove the fuel pump. 2. Remove the screw and the fuel level sender cover.
3. NOTE: Note the routing of the fuel level sender wire for installation.
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Remove the heat shrink tube covering the fuel level sender wire electrical connector.
4. Disconnect the fuel level sender wire electrical connector.
5. NOTE: Note the routing of the fuel level sender ground wire for installation.
Disconnect the ground wire and remove the screw and lift up to remove the fuel level sender.
Installation
1. Route the fuel level sender ground wire along the fuel pump body.
2. Route the fuel level sender wire through the center of the fuel pump.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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3. NOTE: Both fuel gauge sending wires must be routed behind the metal sending unit plate.
Hook the fuel level sender on the fuel pump and install and tighten the screw. Connect the fuel
level sender unit ground wire.
4. Slide the heat shrink tube onto the wire harness and connect the fuel level sender wire electrical
connector.
5. WARNING: Do not use an open flame to shrink the heat shrink tube. Use a heat gun only. Fuel
residue may be ignited if an open flame is
used. Failure to follow this instruction may result in serious personal injury.
Using a heat gun, shrink the heat shrink tube.
6. Install the fuel level sender cover and screw and tighten the screw. 7. Install the fuel pump.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations
Fuel Tank Pressure Sensor: Locations
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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 (V8-4.6L (2008))
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Fuel Tank Pressure Sensor: Service and Repair
FUEL TANK PRESSURE SENSOR
Removal and Installation
WARNING:
- When working on or near the evaporative emission (EVAP) system, disconnect the battery ground
cable from the battery. The EVAP system contains fuel vapor and condensed fuel vapor, so an
electrical spark may cause a fire or explosion. Failure to follow this instruction may result in serious
personal injury.
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious personal injury.
1. Remove the evaporative emission (EVAP) canister. 2. Remove the fuel tank shield from the fuel
tank.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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3. Disconnect the fuel tank pressure (FTP) sensor electrical connector. 4. Disconnect the 3 FTP
sensor and tube assembly quick connect couplings from the fuel pump module and the vapor vent
valves. 5. Remove the FTP sensor and tube assembly. 6. To install, reverse the removal
procedure. 7. Leak test the EVAP system. 8. Carry out the evaporative emission repair verification
drive cycle.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations
Intake Air Temperature Sensor: Locations
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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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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fuel, spark, and air flow.
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 above. 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.
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 (V8-4.6L (2008))
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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.
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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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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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.
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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 (V8-4.6L (2008))
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#11
Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #11
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Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #21
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Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #22
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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.
Universal HO2S
The universal HO2S, sometimes referred to as a wideband oxygen sensor, uses the typical HO2S
combined with a current controller in the PCM to infer an air/fuel ratio relative to the stoichiometric
air/fuel ratio. This is accomplished by balancing the amount of oxygen ions pumped in or out of a
measurement chamber within the sensor. The typical HO2S within the universal HO2S is used to
detect the oxygen content of the exhaust gas in the measurement chamber. The oxygen content
inside the measurement chamber is maintained at the stoichiometric air/fuel ratio by pumping
oxygen ions in and out of the measurement chamber. As the exhaust gasses get richer or leaner,
the amount of oxygen that must be pumped in or out to maintain a stoichiometric air/fuel ratio in the
measurement chamber varies in proportion to the air/fuel ratio. The amount of current required to
pump the oxygen ions in or out of the measurement chamber is used to measure the air/fuel ratio.
The measured air/fuel ratio is actually the output from the current controller in the PCM and not a
signal that comes directly from the sensor.
The universal HO2S also uses a self-contained reference chamber to make sure an oxygen
differential is always present. The oxygen for the reference chamber is supplied by pumping small
amounts of oxygen ions from the measurement chamber into the reference chamber. The universal
HO2S does not need access to outside air.
Part to part variance is compensated for by placing a resistor in the connector. This resistor is used
to trim the current measured by the current controller in the PCM.
Embedded with the sensing element is the universal H02S heater. The heater allows the engine to
enter closed loop operation sooner. The heating element heats the sensor to a temperature of
780°C (1,436°F). The VPWR circuit supplies voltage to the heater. The PCM controls the heater on
and off by providing the ground to maintain the sensor at the correct temperature for maximum
accuracy.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 3432
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 (V8-4.6L (2008))
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 3433
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 (V8-4.6L (2008))
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 3434
Oxygen Sensor: Service and Repair Catalyst Monitor Sensor
CATALYST MONITOR SENSOR
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3435
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 (V8-4.6L (2008))
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 3436
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 (V8-4.6L (2008))
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
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C121
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 3441
Power Steering Pressure Switch: Description and Operation
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.
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 3445
The tube mounted differential pressure feedback EGR sensor is identical in operation as the larger
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations
Throttle Position Sensor: Locations
View 151-7
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Throttle Position Sensor: Description and Operation
Electronic Throttle Body (ETB) Throttle Position Sensor
The ETB throttle position sensor has 2 signal circuits in the sensor for redundancy. The redundant
ETB throttle position signals are required for increased monitoring. The first ETB throttle 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). The 2 ETB throttle 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. The reference voltage circuit
and the signal return circuit is shared with the reference voltage circuits and signal return circuits
used by the APP 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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3452
Throttle Position Sensor: Service and Repair
THROTTLE POSITION (TP) SENSOR
Heated PCV Fitting
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3453
Throttle Position (TP) Sensor
Removal
Vehicles equipped with a 4.6L (3V) engine 1. Remove the air cleaner (ACL) outlet pipe. 2. Remove
the bolts and position the heated 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 throttle position (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.
Installation
All vehicles
1. CAUTION:
- Do not reuse the throttle position (TP) sensor and screws. A new TP sensor and screws must be
installed. Failure to follow this instruction may result in poor engine performance.
- Do not use a high-speed driver to install the new screws or damage to the throttle position (TP)
sensor may 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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- 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 ACL outlet pipe.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Transmission Position Switch/Sensor: Locations
View 151-7
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Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3461
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3462
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3463
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3464
Symbols (Part 2)
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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 3465
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3466
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3467
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3468
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3469
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
3 = Splice tape
4 = Harness tape
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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 3470
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3471
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3472
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 3473
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Diagram Information and Instructions > Page 3474
C167
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Transmission Position Switch/Sensor: Adjustments
Transmission Range (TR) Sensor Adjustment - 5R55S
Adjust
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever 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 digital transmission range (TR) sensor electrical
connector.
4. Disconnect the digital TR sensor electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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5. Remove the selector lever cable end from the manual control lever.
6. Remove the outer manual control lever nut and the 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 lb-inch).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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9. Install the outer manual lever and nut.
^ Tighten to 48 Nm (35 lb-ft).
10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable
bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable
to make sure that it is locked into the selector lever cable 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 selector lever cable end is correctly installed.
Install the selector lever cable end onto the manual control lever.
11. Reconnect the digital TR sensor electrical connector.
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12. Move the rubber boot back over the TR electrical connector.
13. NOTE: If the selector lever cable shield is loose on the selector lever cable, replace the selector
lever cable shield.
Install the selector lever cable shield.
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 (V8-4.6L (2008))
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Transmission Position Switch/Sensor: Service and Repair
Digital Transmission Range (TR) Sensor - 5R55S
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by
prying on the side of the selector lever cable shield closest to the boot, then sliding the selector
lever
cable shield away from the boot.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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3. Move the rubber boot back to gain access to the digital transmission range (TR) sensor electrical
connector.
4. Disconnect the digital TR sensor electrical connector.
5. Remove the selector lever cable from the manual control lever.
6. Remove the outer manual control lever.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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3481
7. Remove the digital TR sensor.
Installation
1. CAUTION: The digital transmission range (TR) 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. ^
Tighten to 8 Nm (71 lb-inch).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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3. Install the outer manual lever.
^ Tighten to 48 Nm (35 lb-ft).
4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen
for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that
it is locked into the selector lever cable 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
selector lever cable end is correctly installed.
Install the selector lever cable to the manual control lever.
5. Connect the digital TR sensor electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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6. Move the rubber boot back over the TR sensor electrical connector.
7. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector
lever cable shield.
Install the selector lever cable shield.
8. Verify that the selector lever cable is adjusted correctly.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation
Vehicle Speed Sensor: Description and Operation
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.
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Locations
Throttle Position Sensor: Locations
View 151-7
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View 151-9
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C189
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Locations > Page 3492
Throttle Position Sensor: Description and Operation
Electronic Throttle Body (ETB) Throttle Position Sensor
The ETB throttle position sensor has 2 signal circuits in the sensor for redundancy. The redundant
ETB throttle position signals are required for increased monitoring. The first ETB throttle 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). The 2 ETB throttle 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. The reference voltage circuit
and the signal return circuit is shared with the reference voltage circuits and signal return circuits
used by the APP 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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Locations > Page 3493
Throttle Position Sensor: Service and Repair
THROTTLE POSITION (TP) SENSOR
Heated PCV Fitting
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Locations > Page 3494
Throttle Position (TP) Sensor
Removal
Vehicles equipped with a 4.6L (3V) engine 1. Remove the air cleaner (ACL) outlet pipe. 2. Remove
the bolts and position the heated 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 throttle position (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.
Installation
All vehicles
1. CAUTION:
- Do not reuse the throttle position (TP) sensor and screws. A new TP sensor and screws must be
installed. Failure to follow this instruction may result in poor engine performance.
- Do not use a high-speed driver to install the new screws or damage to the throttle position (TP)
sensor may 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Component Information > Locations > Page 3495
- 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 ACL outlet pipe.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations
Transmission Position Switch/Sensor: Locations
View 151-7
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Switch/Sensor, A/T > Component Information > Locations > Page 3499
View 151-11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3502
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3503
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3504
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3505
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3506
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3507
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3508
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3509
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3510
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3511
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3512
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3513
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3514
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3515
C167
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Page 3516
Transmission Position Switch/Sensor: Adjustments
Transmission Range (TR) Sensor Adjustment - 5R55S
Adjust
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever 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 digital transmission range (TR) sensor electrical
connector.
4. Disconnect the digital TR sensor electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Page 3517
5. Remove the selector lever cable end from the manual control lever.
6. Remove the outer manual control lever nut and the 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 lb-inch).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Page 3518
9. Install the outer manual lever and nut.
^ Tighten to 48 Nm (35 lb-ft).
10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable
bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable
to make sure that it is locked into the selector lever cable 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 selector lever cable end is correctly installed.
Install the selector lever cable end onto the manual control lever.
11. Reconnect the digital TR sensor electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Page 3519
12. Move the rubber boot back over the TR electrical connector.
13. NOTE: If the selector lever cable shield is loose on the selector lever cable, replace the selector
lever cable shield.
Install the selector lever cable shield.
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Page 3520
Transmission Position Switch/Sensor: Service and Repair
Digital Transmission Range (TR) Sensor - 5R55S
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by
prying on the side of the selector lever cable shield closest to the boot, then sliding the selector
lever
cable shield away from the boot.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Switch/Sensor, A/T > Component Information > Diagrams > Page 3521
3. Move the rubber boot back to gain access to the digital transmission range (TR) sensor electrical
connector.
4. Disconnect the digital TR sensor electrical connector.
5. Remove the selector lever cable from the manual control lever.
6. Remove the outer manual control lever.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Page 3522
7. Remove the digital TR sensor.
Installation
1. CAUTION: The digital transmission range (TR) 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. ^
Tighten to 8 Nm (71 lb-inch).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Switch/Sensor, A/T > Component Information > Diagrams > Page 3523
3. Install the outer manual lever.
^ Tighten to 48 Nm (35 lb-ft).
4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen
for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that
it is locked into the selector lever cable 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
selector lever cable end is correctly installed.
Install the selector lever cable to the manual control lever.
5. Connect the digital TR sensor electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Page 3524
6. Move the rubber boot back over the TR sensor electrical connector.
7. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector
lever cable shield.
Install the selector lever cable shield.
8. Verify that the selector lever cable is adjusted correctly.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 > Page 3529
C1452
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Diagrams > Page 3530
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 (CKP) sensor 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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Diagrams > Page 3531
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.
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 (V8-4.6L (2008))
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 variable camshaft timing (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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Description and Operation
Vehicle Speed Sensor: Description and Operation
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.
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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
powertrain control module (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/Catalyst Efficiency Monitor
For 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).
Catalytic Converter
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Page 3552
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Page 3553
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 Exhaust System for the exhaust system-exploded view.
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 PCM with 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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Control Valve > Component Information > Diagrams
C1029
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Control Valve > Component Information > Diagrams > Page 3558
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Control Valve > Component Information > Diagrams > Page 3559
Canister Purge Control Valve: Service and Repair
EVAPORATIVE EMISSION CANISTER PURGE VALVE
Removal and Installation
WARNING:
- When working on or near the evaporative emission (EVAP) system, disconnect the battery ground
cable from the battery. The EVAP system contains fuel vapor and condensed fuel vapor, so an
electrical spark may cause a fire or explosion. Failure to follow this instruction may result in serious
personal injury.
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious 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 EVAP system. See: Testing and Inspection 8. Carry out the
evaporative emission repair verification drive cycle.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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:
- When working on or near the evaporative emission (EVAP) system, disconnect the battery ground
cable from the battery. The EVAP system contains fuel vapor and condensed fuel vapor, so an
electrical spark may cause a fire or explosion. Failure to follow this instruction may result in serious
personal injury.
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious 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 (EVAP) system. See: Testing and Inspection 8. Carry out the
evaporative emission repair drive cycle.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Check Valve > Component Information > Diagrams
C450
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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:
- When working on or near the evaporative emission (EVAP) system, disconnect the battery ground
cable from the battery. The EVAP system contains fuel vapor and condensed fuel vapor, so an
electrical spark may cause a fire or explosion. Failure to follow this instruction may result in serious
personal injury.
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious 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 (FTP) 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 EVAP system. See: Testing and Inspection
10. Carry out the evaporative emission repair verification drive cycle.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Solenoid, Evaporative System > Component Information > Description and Operation
Leak Detection Solenoid: Description and Operation
CANISTER VENT (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 (V8-4.6L (2008))
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:
- When working on or near the evaporative emission (EVAP) system, disconnect the battery ground
cable from the battery. The EVAP system contains fuel vapor and condensed fuel vapor, so an
electrical spark may cause a fire or explosion. Failure to follow this instruction may result in serious
personal injury.
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious personal injury.
NOTE: Use only water-based lubricants on the vapor hoses.
1. With the vehicle in NEUTRAL, position it on 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 (EVAP) system. See: Testing and Inspection 7. Carry out the
evaporative emission repair drive cycle.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Control Module > Component Information > Locations
View 151-7
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Control Module > Component Information > Locations > Page 3579
C1450
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Description and Operation
EGR Valve: Description and Operation
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).
Exhaust Gas Recirculation (EGR) System Module (ESM)
ESM
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Description and Operation > Page 3589
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.
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 3593
The tube mounted differential pressure feedback EGR sensor is identical in operation as the larger
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Positive Crankcase Ventilation Valve > Component Information > Diagrams
C190
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Relays and Modules - Emission Control
Systems > EGR Control Module > Component Information > Locations
View 151-7
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Relays and Modules - Emission Control
Systems > EGR Control Module > Component Information > Locations > Page 3602
C1450
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 3607
The tube mounted differential pressure feedback EGR sensor is identical in operation as the larger
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 (V8-4.6L (2008))
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 (KOEO)..............................................................................................................
.............................................207-276 kPa (30-40 psi) Engine running.................................................
..................................................................................................................................207-276 kPa
(30-40 psi)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information
> Specifications > Page 3612
Fuel Pressure: Testing and Inspection
FUEL SYSTEM PRESSURE TEST
Special Tool(s)
Special Tool(s)
WARNING:
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious personal injury.
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the
fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under
high pressure, even when the engine is not running. Failure to follow this instruction may result in
serious 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 component. Highly flammable mixtures are always
present and may be ignited. Failure to follow these instructions may result in serious personal
injury.
- When handling fuel, always observe fuel handling precautions and be prepared in the event of
fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources.
Failure to follow these instructions may result in serious personal injury.
1. Disconnect the fuel supply tube-to-fuel rail spring lock coupling.
2. NOTE: 4.6L shown, 4.0L similar.
Install the special tool in line between the fuel supply tube and fuel rail.
3. NOTE: The inertia fuel shutoff (IFS) switch electrical connector was disconnected during fuel
system pressure release.
Connect the IFS switch electrical connector.
4. 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.
5. Test the fuel system pressure to make sure it is within the specified range.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information
> Specifications > Page 3613
6. NOTE:
- 4.6L shown, 4.0L similar.
- Open the drain valve slowly to relieve the fuel system pressure. This may drain fuel from the
system. Place the fuel in a suitable container.
Upon completion of the fuel system pressure test, open the drain valve on the special tool and
relieve the fuel system pressure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious personal injury.
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the
fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under
high pressure, even when the engine is not running. Failure to follow this instruction may result in
serious 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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Specifications
Idle Speed: Specifications
Typical Diagnostic Reference Value
Measured/PID Values 630 - 850 RPM ................................................................................................
...................................................................................................... Hot Idle
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Specifications
Torque Specifications
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Service and Repair > Accelerator Pedal - Fixed > Page 3625
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor >
Component Information > Locations
View 151-13
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor >
Component Information > Locations > Page 3629
C2040
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor >
Component Information > Locations > Page 3630
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
amount of torque requested by the operator. Depending on the application either a 2-track or
3-track APP sensor is used.
2-Track APP Sensor
2-Track APP Sensor
There are 2 pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive
slope (increasing angle, increasing voltage), but are offset and increase at different rates. The 2
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. If a concern is present with one of the circuits the other input is used. There are 2
reference voltage circuits, 2 signal return circuits, and 2 signal circuits (a total of 6 circuits and pins)
between the PCM and the APP sensor assembly. The reference voltage circuits and the signal
return circuits are shared with the reference voltage circuit and signal return circuit used by the
electronic throttle body (ETB) throttle position sensor. The pedal position signal is converted 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.
3-Track APP Sensor
Typical 3-Track APP Sensor
There are 3 pedal position signals in the sensor. Signal 1, APP1, has a negative slope (increasing
angle, decreasing voltage) and signals 2 and 3, 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. 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. If a concern is present with one of the circuits
the other inputs are used. The pedal position signal is converted 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. There are 2 reference voltage circuits, 2 signal return circuits, and 3 signal
circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. The
reference voltage circuits and the signal return circuits are shared with the reference voltage circuit
and signal return circuit used by the electronic throttle body (ETB) throttle position sensor.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Coolant Expansion Tank
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair > Page 3635
Intake Air System Components (4.0L SOHC)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair > Page 3636
Intake Air System Components - 4.6L (3V)
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 (ACL) outlet pipe.
Vehicles equipped with a 4.6L (3V) engine
2. Detach the wiring harness retainer from the coolant expansion tank.
All vehicles
3. Loosen the clamp and disconnect the ACL outlet pipe from the ACL. 4. Unclip and remove the
ACL cover. 5. Remove the ACL.
6. NOTE: Clean the inside of the ACL tray.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Locations
Air Flow Meter/Sensor: Locations
View 151-8
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Locations > Page 3640
View 151-9
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Locations > Page 3641
C1454
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Locations > Page 3642
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Locations > Page 3643
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Locations > Page 3644
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 sensor.
- To install, tighten to 2 Nm (18 lb-in).
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 there is a concern in the
EVAP system due to the fuel filler cap or capless fuel tank filler pipe 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 (V8-4.6L (2008))
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, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious personal injury.
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the
fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under
high pressure, even when the engine is not running. Failure to follow this instruction may result in
serious 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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Specifications > Electrical Specifications
Fuel Injector: Electrical Specifications
Fuel Injector Resistance ......................................................................................................................
............................................................. 11 - 18 Ohms
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Specifications > Electrical Specifications > Page 3656
Fuel Injector: Pressure, Vacuum and Temperature Specifications
Fuel Injector Flow and Leakage ..................................................................... Refer to Pinpoint Test
HC12 and HC13 at Computers and Control Systems.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1
C181
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 3659
C182
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 3660
C183
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 3661
C184
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 3662
Fuel Injector: Diagrams
C181
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 3663
C182
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 3664
C183
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 3665
C184
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 3666
C185
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 3667
C186
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 3668
C187
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 3669
C188
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Page 3670
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Page 3671
Fuel Injector: Service and Repair
FUEL RAIL
Part 1
Part 2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Page 3672
Exploded View
Removal and Installation
WARNING:
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious personal injury.
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the
fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under
high pressure, even when the engine is not running. Failure to follow this instruction may result in
serious personal injury.
NOTE: During the repair or installation of new 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 caps, tape and other protective materials prior to installation.
1. Release the fuel system pressure. 2. Disconnect the fuel supply tube spring lock coupling. 3.
Detach the 2 PCV coolant hose retainers from the fuel rail stud bolts and position the hose aside.
4. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum hose.
5. Disconnect the 8 fuel injector electrical connectors. 6. Remove the fuel rail stud bolts.
- To install, tighten to 10 Nm (89 lb-in).
7. Remove the fuel rail and fuel injectors as an assembly from the intake manifold.
8. NOTE: The fuel injector clip can be reused if it is not damaged during removal. If the clip is
reused, the 2 sides of the clip should be squeezed
back into shape by placing it between index finger and thumb.
Remove the retaining clips and fuel injectors from the fuel rail.
9. CAUTION:
- O-ring seals are made of special fuel-resistant material. Fuel will damage ordinary O-ring seals
and may cause the fuel system to leak.
- Do not reuse O-ring seals. The removal and installation process may damage the used O-ring
seals, and cause the fuel system to leak.
Remove and discard the fuel injector O-ring seals.
10. To install, reverse the removal procedure.
- Lubricate the new upper and lower fuel injector O-ring seals with clean engine oil prior to
installation.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious personal injury.
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the
fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under
high pressure, even when the engine is not running. Failure to follow this instruction may result in
serious 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 component. Highly flammable mixtures are always
present and may be ignited. Failure to follow these instructions may result in serious personal
injury.
- When handling fuel, always observe fuel handling precautions and be prepared in the event of
fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources.
Failure to follow these instructions may result in serious personal injury.
CAUTION:
- Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is
essential that absolute cleanliness is observed when working with these components or component
damage may occur. Always install 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 or damage
to the tube or connector retaining clip may occur. Apply clean engine oil to the end of the tube
before inserting the tube into the connector.
1. Release the fuel system pressure. 2. Disconnect the battery ground cable.
3. Disconnect the safety clip from the fuel tube.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 3677
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. NOTE:
- 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.
- Lubricate the spring lock coupling with clean engine oil.
Align the fuel tube spring lock coupling and push together until a click is heard.
3. Pull on the spring lock coupling to make sure it is fully seated. Install the fuel tube safety clip on
the male end.
Disconnect - Type II
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 3678
WARNING:
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious personal injury.
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the
fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under
high pressure, even when the engine is not running. Failure to follow this instruction may result in
serious 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 component. Highly flammable mixtures are always
present and may be ignited. Failure to follow these instructions may result in serious personal
injury.
- When handling fuel, always observe fuel handling precautions and be prepared in the event of
fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources.
Failure to follow these instructions may result in serious personal injury.
CAUTION:
- Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is
essential that absolute cleanliness is observed when working with these components or component
damage may occur. Always install 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 or damage
to the tube or connector retaining clip may occur. Apply clean engine oil to the end of the tube
before inserting the tube into the connector.
1. Release the fuel system pressure. 2. Disconnect the battery ground cable.
3. Remove the fuel tube safety clip.
4. Install the special tool.
5. Close and push the special tool into the open side of the cage.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 3679
6. Separate the spring lock coupling.
Connect - Type II
1. Inspect and clean both spring lock coupling ends. Install new O-ring seals and garter springs if
necessary.
2. NOTE:
- 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.
- Apply clean engine oil to O-ring seals.
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 tube.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 3680
4. Install the fuel tube safety clip
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 3681
Fuel Line Coupler: Service and Repair Quick Connect Coupling
QUICK CONNECT COUPLING
Disconnect - Type I
WARNING:
- When working on or near the evaporative emission (EVAP) system, disconnect the battery ground
cable from the battery. The EVAP system contains fuel vapor and condensed fuel vapor, so an
electrical spark may cause a fire or explosion. Failure to follow this instruction may result in serious
personal injury.
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious personal injury.
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the
fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under
high pressure, even when the engine is not running. Failure to follow this instruction may result in
serious 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 component. Highly flammable mixtures are always
present and may be ignited. Failure to follow these instructions may result in serious personal
injury.
- When handling fuel, always observe fuel handling precautions and be prepared in the event of
fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources.
Failure to follow these instructions may result in serious personal injury.
CAUTION:
- Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is
essential that absolute cleanliness is observed when working with these components or component
damage may occur. Always install 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 or damage
to the tube or connector retaining clip may occur. Apply clean engine oil to the end of the tube
before inserting the tube into the connector.
- Do not use any tools. The use of tools may cause a deformity in the clip components which may
cause fuel leaks.
NOTE: During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor
openings must be capped, taped or otherwise appropriately protected to prevent the ingress of dirt
or other contamination. All caps, tape and other protective materials must 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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 3682
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. NOTE:
- 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.
- 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 3683
Disconnect - Type II
WARNING:
- When working on or near the evaporative emission (EVAP) system, disconnect the battery ground
cable from the battery. The EVAP system contains fuel vapor and condensed fuel vapor, so an
electrical spark may cause a fire or explosion. Failure to follow this instruction may result in serious
personal injury.
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious personal injury.
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the
fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under
high pressure, even when the engine is not running. Failure to follow this instruction may result in
serious 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 component. Highly flammable mixtures are always
present and may be ignited. Failure to follow these instructions may result in serious personal
injury.
- When handling fuel, always observe fuel handling precautions and be prepared in the event of
fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources.
Failure to follow these instructions may result in serious personal injury.
CAUTION:
- Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is
essential that absolute cleanliness is observed when working with these components or component
damage may occur. Always install 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 or damage
to the tube or connector retaining clip may occur. Apply clean engine oil to the end of the tube
before inserting the tube into the connector.
- Do not use any tools. The use of tools may cause a deformity in the clip components which may
cause fuel leaks.
NOTE: During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor
openings must be capped, taped or otherwise appropriately protected to prevent the ingress of dirt
or other contamination. All caps, tape and other protective materials must 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.
2. NOTE:
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 3684
- 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.
- 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: Do not smoke, carry lighted tobacco or have an open flame of any type when working
on or near any fuel-related component. Highly flammable mixtures are always present and may be
ignited. Failure to follow these instructions may result in serious personal injury.
CAUTION:
- Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is
essential that absolute cleanliness is observed when working with these components or component
damage may occur. Always install 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 or damage
to the tube or connector retaining clip may occur. Apply clean engine oil to the end of the tube
before inserting the tube into the connector.
- Do not use any tools. The use of tools may cause a deformity in the clip components which may
cause fuel leaks.
NOTE: During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor
openings must be capped, taped or otherwise appropriately protected to prevent the ingress of dirt
or other contamination. All caps, tape and other protective materials must be removed prior to
installation.
1. Release the locking tab on the quick connect coupling.
2. 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 3685
2. NOTE:
- 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.
- 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:
- When working on or near the evaporative emission (EVAP) system, disconnect the battery ground
cable from the battery. The EVAP system contains fuel vapor and condensed fuel vapor, so an
electrical spark may cause a fire or explosion. Failure to follow this instruction may result in serious
personal injury.
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious personal injury.
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the
fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under
high pressure, even when the engine is not running. Failure to follow this instruction may result in
serious 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 component. Highly flammable mixtures are always
present and may be ignited. Failure to follow these instructions may result in serious personal
injury.
- When handling fuel, always observe fuel handling precautions and be prepared in the event of
fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources.
Failure to follow these instructions may result in serious personal injury.
CAUTION:
- Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is
essential that absolute cleanliness is observed when working with these components or component
damage may occur. Always install 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 or damage
to the tube or connector retaining clip may occur. Apply clean engine oil to the end of the tube
before inserting the tube into the connector.
- Do not use any tools. The use of tools may cause a deformity in the clip components which may
cause fuel leaks.
NOTE: During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor
openings must be capped, taped or otherwise appropriately protected to prevent the ingress of dirt
or other contamination. All caps, tape and other protective materials must be removed prior to
installation.
1. If servicing a liquid fuel tube, release the fuel system pressure. 2. Disconnect the battery ground
cable.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 3686
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. NOTE:
- 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.
- 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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch >
Component Information > Locations
Fuel Pressure Sensor/Switch: Locations
View 151-7
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch >
Component Information > Locations > Page 3690
View 151-9
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch >
Component Information > Locations > Page 3691
C173
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch >
Component Information > Locations > Page 3692
Fuel Pressure Sensor/Switch: 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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch >
Component Information > Locations > Page 3693
Fuel Pressure Sensor/Switch: Service and Repair
FUEL RAIL PRESSURE AND TEMPERATURE SENSOR
Removal and Installation
WARNING:
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious personal injury.
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the
fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under
high pressure, even when the engine is not running. Failure to follow this instruction may result in
serious personal injury.
1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel
rail pressure and temperature sensor electrical connector. 4. Disconnect the fuel rail pressure and
temperature sensor vacuum hose connector. 5. Remove the 2 bolts and the fuel rail pressure and
temperature sensor.
- To install, tighten to 6 Nm (53 lb-in).
6. To install, reverse the removal procedure.
- Inspect the O-ring seal and install a new O-ring seal if necessary.
- Lubricate the O-ring seal with clean engine oil.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 (KOEO)..............................................................................................................
.............................................207-276 kPa (30-40 psi) Engine running.................................................
..................................................................................................................................207-276 kPa
(30-40 psi)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Specifications > Page 3701
Fuel Pressure: Testing and Inspection
FUEL SYSTEM PRESSURE TEST
Special Tool(s)
Special Tool(s)
WARNING:
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious personal injury.
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the
fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under
high pressure, even when the engine is not running. Failure to follow this instruction may result in
serious 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 component. Highly flammable mixtures are always
present and may be ignited. Failure to follow these instructions may result in serious personal
injury.
- When handling fuel, always observe fuel handling precautions and be prepared in the event of
fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources.
Failure to follow these instructions may result in serious personal injury.
1. Disconnect the fuel supply tube-to-fuel rail spring lock coupling.
2. NOTE: 4.6L shown, 4.0L similar.
Install the special tool in line between the fuel supply tube and fuel rail.
3. NOTE: The inertia fuel shutoff (IFS) switch electrical connector was disconnected during fuel
system pressure release.
Connect the IFS switch electrical connector.
4. 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.
5. Test the fuel system pressure to make sure it is within the specified range.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Specifications > Page 3702
6. NOTE:
- 4.6L shown, 4.0L similar.
- Open the drain valve slowly to relieve the fuel system pressure. This may drain fuel from the
system. Place the fuel in a suitable container.
Upon completion of the fuel system pressure test, open the drain valve on the special tool and
relieve the fuel system pressure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control
Unit > Component Information > Locations
Fuel Pump Control Unit: Locations
View 151-24
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control
Unit > Component Information > Locations > Page 3706
View 151-27
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control
Unit > Component Information > Locations > Page 3707
C4033
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control
Unit > Component Information > Locations > Page 3708
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Locations > Page 3712
Fuel Pump Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Service and Repair
Fuel Rail: Service and Repair
FUEL RAIL
Part 1
Part 2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Service and Repair > Page 3716
Exploded View
Removal and Installation
WARNING:
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious personal injury.
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the
fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under
high pressure, even when the engine is not running. Failure to follow this instruction may result in
serious personal injury.
NOTE: During the repair or installation of new 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 caps, tape and other protective materials prior to installation.
1. Release the fuel system pressure. 2. Disconnect the fuel supply tube spring lock coupling. 3.
Detach the 2 PCV coolant hose retainers from the fuel rail stud bolts and position the hose aside.
4. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum hose.
5. Disconnect the 8 fuel injector electrical connectors. 6. Remove the fuel rail stud bolts.
- To install, tighten to 10 Nm (89 lb-in).
7. Remove the fuel rail and fuel injectors as an assembly from the intake manifold.
8. NOTE: The fuel injector clip can be reused if it is not damaged during removal. If the clip is
reused, the 2 sides of the clip should be squeezed
back into shape by placing it between index finger and thumb.
Remove the retaining clips and fuel injectors from the fuel rail.
9. CAUTION:
- O-ring seals are made of special fuel-resistant material. Fuel will damage ordinary O-ring seals
and may cause the fuel system to leak.
- Do not reuse O-ring seals. The removal and installation process may damage the used O-ring
seals, and cause the fuel system to leak.
Remove and discard the fuel injector O-ring seals.
10. To install, reverse the removal procedure.
- Lubricate the new upper and lower fuel injector O-ring seals with clean engine oil prior to
installation.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > Page 3720
Explorer Sport Trac (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > Page 3721
Explorer/Mountaineer (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > Page 3722
Explorer/Mountaineer (Part 2)
Exploded View
Removal and Installation
WARNING:
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious personal injury.
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the
fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under
high pressure, even when the engine is not running. Failure to follow this instruction may result in
serious personal injury.
- When handling fuel, always observe fuel handling precautions and be prepared in the event of
fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources.
Failure to follow these instructions may result in serious personal injury.
NOTE: During the repair or replacement of fuel-related components, all liquid and vapor fuel
openings must be capped, taped or otherwise appropriately protected to prevent the ingress of dirt
or other contamination. All caps, tape and other protective materials must be removed prior to
installation.
1. With the vehicle in NEUTRAL, position it on a 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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair > Page 3727
Explorer Sport Trac (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair > Page 3728
Explorer/Mountaineer (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair > Page 3729
Explorer/Mountaineer (Part 2)
Exploded View
Removal and Installation
All vehicles
WARNING:
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious personal injury.
- When handling fuel, always observe fuel handling precautions and be prepared in the event of
fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources.
Failure to follow these instructions may result in serious personal injury.
- Remove the fuel filler cap slowly. The fuel system may be under pressure. If the fuel filler cap is
venting vapor or if you hear a hissing sound, wait until it stops before completely removing the fuel
filler cap. Otherwise, fuel may spray out. Failure to follow these instructions may result in serious
personal injury.
NOTE: During the repair or replacement of fuel-related components, all liquid and vapor fuel
openings must be capped, taped or otherwise appropriately protected to prevent the ingress of dirt
or other contamination. All caps, tape and other protective materials must be removed prior to
installation.
1. Drain the fuel tank.
2. NOTE: The fuel tank filler pipe hose between the fuel tank filler pipe and the fuel tank is
serviceable separately. The fuel tank filler pipe does not
have to be removed from the vehicle to service the fuel tank filler pipe hose.
If necessary, loosen the fuel tank filler pipe hose clamp at the fuel tank and disconnect the hose
and remove from the vehicle. To install, tighten to 3 Nm (27 lb-in).
3. If equipped, open the fuel tank filler cap. 4. Remove the 3 bolts.
- To install, tighten to 1 Nm (9 lb-in).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair > Page 3730
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.
Explorer/Mountaineer late build vehicles
6. Remove the fuel tank filler pipe upper retainer.
All vehicles
7. Disconnect the fuel filler pipe vapor tube-to-fuel pressure sensor and vapor tube assembly quick
connect coupling. 8. Disconnect the rear axle vent hose. 9. Disconnect the dust separator hose.
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 3739
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 3745
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Diagrams
Fuel Gauge Sender: Diagrams
C434A
C434B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Diagrams > Page 3749
Fuel Gauge Sender: Description and Operation
Fuel Pump (FP) Module
Typical Electronic Returnless Fuel Pump (FP) Module
Typical Mechanical Returnless Fuel Pump (FP) Module
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Diagrams > Page 3750
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Diagrams > Page 3751
Fuel Gauge Sender: Service and Repair
FUEL LEVEL SENDER
Removal
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working
on or near any fuel-related component. Highly flammable mixtures are always present and may be
ignited. Failure to follow these instructions may result in serious personal injury.
1. Remove the fuel pump. 2. Remove the screw and the fuel level sender cover.
3. NOTE: Note the routing of the fuel level sender wire for installation.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Diagrams > Page 3752
Remove the heat shrink tube covering the fuel level sender wire electrical connector.
4. Disconnect the fuel level sender wire electrical connector.
5. NOTE: Note the routing of the fuel level sender ground wire for installation.
Disconnect the ground wire and remove the screw and lift up to remove the fuel level sender.
Installation
1. Route the fuel level sender ground wire along the fuel pump body.
2. Route the fuel level sender wire through the center of the fuel pump.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Diagrams > Page 3753
3. NOTE: Both fuel gauge sending wires must be routed behind the metal sending unit plate.
Hook the fuel level sender on the fuel pump and install and tighten the screw. Connect the fuel
level sender unit ground wire.
4. Slide the heat shrink tube onto the wire harness and connect the fuel level sender wire electrical
connector.
5. WARNING: Do not use an open flame to shrink the heat shrink tube. Use a heat gun only. Fuel
residue may be ignited if an open flame is
used. Failure to follow this instruction may result in serious personal injury.
Using a heat gun, shrink the heat shrink tube.
6. Install the fuel level sender cover and screw and tighten the screw. 7. Install the fuel pump.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting
Straps > Component Information > Service and Repair > Page 3757
Explorer Sport Trac (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting
Straps > Component Information > Service and Repair > Page 3758
Explorer/Mountaineer (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting
Straps > Component Information > Service and Repair > Page 3759
Explorer/Mountaineer (Part 2)
Exploded View
Removal and Installation
All vehicles
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working
on or near any fuel-related component. Highly flammable mixtures are always present and may be
ignited. Failure to follow these instructions may result in serious personal injury.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting
Straps > Component Information > Service and Repair > Page 3760
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 (V8-4.6L (2008))
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
Typical Mechanical Returnless Fuel Pump (FP) Module
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component
Information > Description and Operation > Page 3764
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor >
Component Information > Locations
Fuel Temperature Sensor: Locations
View 151-7
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor >
Component Information > Locations > Page 3768
View 151-9
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor >
Component Information > Locations > Page 3769
C173
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor >
Component Information > Locations > Page 3770
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor >
Component Information > Locations > Page 3771
Fuel Temperature Sensor: Service and Repair
FUEL RAIL PRESSURE AND TEMPERATURE SENSOR
Removal and Installation
WARNING:
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious personal injury.
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the
fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under
high pressure, even when the engine is not running. Failure to follow this instruction may result in
serious personal injury.
1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel
rail pressure and temperature sensor electrical connector. 4. Disconnect the fuel rail pressure and
temperature sensor vacuum hose connector. 5. Remove the 2 bolts and the fuel rail pressure and
temperature sensor.
- To install, tighten to 6 Nm (53 lb-in).
6. To install, reverse the removal procedure.
- Inspect the O-ring seal and install a new O-ring seal if necessary.
- Lubricate the O-ring seal with clean engine oil.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Locations
View 151-13
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Locations > Page 3778
C282
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Locations > Page 3779
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, Roadside Emergencies for the location of the IFS switch.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Locations > Page 3780
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 (V8-4.6L (2008))
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
Coolant Expansion Tank
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component
Information > Service and Repair > Page 3784
Intake Air System Components (4.0L SOHC)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component
Information > Service and Repair > Page 3785
Intake Air System Components - 4.6L (3V)
Exploded View
Removal and Installation
Vehicles equipped with a 4.0L SOHC engine
1. Detach the wiring harness retainer from the 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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Locations > Page 3789
Main Relay (Computer/Fuel System): Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Fuel Pump Control Unit: Locations
View 151-24
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3794
View 151-27
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3795
C4033
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3796
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 3800
Fuel Pump Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 3804
Main Relay (Computer/Fuel System): Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 151-13
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3809
C2040
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3810
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
amount of torque requested by the operator. Depending on the application either a 2-track or
3-track APP sensor is used.
2-Track APP Sensor
2-Track APP Sensor
There are 2 pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive
slope (increasing angle, increasing voltage), but are offset and increase at different rates. The 2
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. If a concern is present with one of the circuits the other input is used. There are 2
reference voltage circuits, 2 signal return circuits, and 2 signal circuits (a total of 6 circuits and pins)
between the PCM and the APP sensor assembly. The reference voltage circuits and the signal
return circuits are shared with the reference voltage circuit and signal return circuit used by the
electronic throttle body (ETB) throttle position sensor. The pedal position signal is converted 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.
3-Track APP Sensor
Typical 3-Track APP Sensor
There are 3 pedal position signals in the sensor. Signal 1, APP1, has a negative slope (increasing
angle, decreasing voltage) and signals 2 and 3, 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. 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. If a concern is present with one of the circuits
the other inputs are used. The pedal position signal is converted 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. There are 2 reference voltage circuits, 2 signal return circuits, and 3 signal
circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. The
reference voltage circuits and the signal return circuits are shared with the reference voltage circuit
and signal return circuit used by the electronic throttle body (ETB) throttle position sensor.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Air Flow Meter/Sensor: Locations
View 151-8
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3814
View 151-9
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3815
C1454
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3816
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 (V8-4.6L (2008))
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 3817
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 (V8-4.6L (2008))
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 3818
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 sensor.
- To install, tighten to 2 Nm (18 lb-in).
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Pressure Sensor/Switch: Locations
View 151-7
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Page 3822
View 151-9
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Page 3823
C173
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Page 3824
Fuel Pressure Sensor/Switch: 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 (V8-4.6L (2008))
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 > Page 3825
Fuel Pressure Sensor/Switch: Service and Repair
FUEL RAIL PRESSURE AND TEMPERATURE SENSOR
Removal and Installation
WARNING:
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious personal injury.
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the
fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under
high pressure, even when the engine is not running. Failure to follow this instruction may result in
serious personal injury.
1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel
rail pressure and temperature sensor electrical connector. 4. Disconnect the fuel rail pressure and
temperature sensor vacuum hose connector. 5. Remove the 2 bolts and the fuel rail pressure and
temperature sensor.
- To install, tighten to 6 Nm (53 lb-in).
6. To install, reverse the removal procedure.
- Inspect the O-ring seal and install a new O-ring seal if necessary.
- Lubricate the O-ring seal with clean engine oil.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations
Fuel Temperature Sensor: Locations
View 151-7
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3829
View 151-9
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3830
C173
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3831
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 (V8-4.6L (2008))
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 3832
Fuel Temperature Sensor: Service and Repair
FUEL RAIL PRESSURE AND TEMPERATURE SENSOR
Removal and Installation
WARNING:
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near
any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Failure to follow these instructions may result in serious personal injury.
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the
fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under
high pressure, even when the engine is not running. Failure to follow this instruction may result in
serious personal injury.
1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel
rail pressure and temperature sensor electrical connector. 4. Disconnect the fuel rail pressure and
temperature sensor vacuum hose connector. 5. Remove the 2 bolts and the fuel rail pressure and
temperature sensor.
- To install, tighten to 6 Nm (53 lb-in).
6. To install, reverse the removal procedure.
- Inspect the O-ring seal and install a new O-ring seal if necessary.
- Lubricate the O-ring seal with clean engine oil.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 151-13
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3836
C282
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3837
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, Roadside Emergencies for the location of the IFS switch.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3838
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations
Throttle Position Sensor: Locations
View 151-7
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3842
View 151-9
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3843
C189
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3844
Throttle Position Sensor: Description and Operation
Electronic Throttle Body (ETB) Throttle Position Sensor
The ETB throttle position sensor has 2 signal circuits in the sensor for redundancy. The redundant
ETB throttle position signals are required for increased monitoring. The first ETB throttle 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). The 2 ETB throttle 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. The reference voltage circuit
and the signal return circuit is shared with the reference voltage circuits and signal return circuits
used by the APP 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 (V8-4.6L (2008))
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 3845
Throttle Position Sensor: Service and Repair
THROTTLE POSITION (TP) SENSOR
Heated PCV Fitting
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3846
Throttle Position (TP) Sensor
Removal
Vehicles equipped with a 4.6L (3V) engine 1. Remove the air cleaner (ACL) outlet pipe. 2. Remove
the bolts and position the heated 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 throttle position (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.
Installation
All vehicles
1. CAUTION:
- Do not reuse the throttle position (TP) sensor and screws. A new TP sensor and screws must be
installed. Failure to follow this instruction may result in poor engine performance.
- Do not use a high-speed driver to install the new screws or damage to the throttle position (TP)
sensor may 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3847
- 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 ACL outlet pipe.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
CAUTION: The throttle body (TB) 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 TB or the TB may be damaged.
1. Remove the air cleaner outlet pipe. 2. Disconnect the electronic throttle control electrical
connector. 3. Disconnect the throttle position (TP) sensor electrical connector. 4. Remove the bolts,
the throttle body (TB) and the TB gasket. Discard the gasket.
- To install, tighten to 10 Nm (89 lb-in).
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Locations
Throttle Position Sensor: Locations
View 151-7
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Locations > Page 3854
View 151-9
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Locations > Page 3855
C189
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Locations > Page 3856
Throttle Position Sensor: Description and Operation
Electronic Throttle Body (ETB) Throttle Position Sensor
The ETB throttle position sensor has 2 signal circuits in the sensor for redundancy. The redundant
ETB throttle position signals are required for increased monitoring. The first ETB throttle 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). The 2 ETB throttle 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. The reference voltage circuit
and the signal return circuit is shared with the reference voltage circuits and signal return circuits
used by the APP 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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Locations > Page 3857
Throttle Position Sensor: Service and Repair
THROTTLE POSITION (TP) SENSOR
Heated PCV Fitting
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Locations > Page 3858
Throttle Position (TP) Sensor
Removal
Vehicles equipped with a 4.6L (3V) engine 1. Remove the air cleaner (ACL) outlet pipe. 2. Remove
the bolts and position the heated 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 throttle position (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.
Installation
All vehicles
1. CAUTION:
- Do not reuse the throttle position (TP) sensor and screws. A new TP sensor and screws must be
installed. Failure to follow this instruction may result in poor engine performance.
- Do not use a high-speed driver to install the new screws or damage to the throttle position (TP)
sensor may 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Locations > Page 3859
- 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 ACL outlet pipe.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System >
Variable Induction Control Actuator > Component Information > Description and Operation
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System >
Variable Induction Control Actuator > Component Information > Description and Operation > Page 3864
Variable Induction Control Actuator: Service and Repair
CHARGE MOTION CONTROL VALVE (CMCV)
Removal
1. Remove the intake manifold.
2. NOTE: Do not disconnect the linkages at the intake manifold unless a new intake manifold is
being installed.
Remove and discard the 2 E-clips and disconnect the charge motion control valve (CMCV)
linkages from the CMCV.
3. NOTE: Bent shaft or damaged components will require a new intake manifold.
Rotate each CMCV shaft by hand to verify that they do not stick or bind.
4. Remove the 3 bolts and the CMCV.
Installation
1. Position the CMCV and loosely install the 3 bolts.
- Do not tighten the bolts at this time.
2. Rotate each CMCV shaft so that the plates are in the closed position.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System >
Variable Induction Control Actuator > Component Information > Description and Operation > Page 3865
3. Install the RH and LH CMCV plate alignment locks. 4. Connect the RH and LH CMCV linkages
to the CMCV and install 2 new E-clips. 5. Verify that the CMCV plate alignment locks are still
correctly located and tighten the 3 CMCV bolts.
- Tighten to 10 Nm (89 lb-in).
6. Remove the RH and LH alignment locks. 7. Install the intake manifold. 8. Carry out the key ON
engine OFF (KOEO) self-test.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information >
Specifications
Firing Order: Specifications
Firing order...........................................................................................................................................
...........................................................1-3-7-2-6-5-4-8
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > System Information >
Specifications
Ignition Timing: Specifications
Item.......................................................................................................................................................
..............................................................Specification
Base ignition
timing..............................................................................................................................................10
degrees before top dead center (BTDC)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Locations > Camshaft Position Sensor 1
View 151-9
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Locations > Camshaft Position Sensor 1 > Page 3877
View 151-9
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Locations > Camshaft Position Sensor 1 > Page 3878
View 151-7
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Camshaft Position Sensor
C180
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Camshaft Position Sensor > Page 3881
C1366
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Camshaft Position Sensor > Page 3882
C1367
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Page 3883
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Page 3884
Camshaft Position Sensor: Service and Repair
CAMSHAFT POSITION (CMP) SENSOR
Removal and Installation
RH side
1. Remove the air cleaner (ACL) outlet pipe.
Both sides
2. Disconnect the camshaft position (CMP) sensor electrical connector. 3. Remove the bolt and the
CMP sensor.
- To install, tighten to 10 Nm (89 lb-in).
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations
Crankshaft Position Sensor: Locations
View 151-8
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations > Page 3888
View 151-9
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations > Page 3889
Crankshaft Position Sensor: Diagrams
C101
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations > Page 3890
C1120
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations > Page 3891
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 decelerations between teeth.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations > Page 3892
Crankshaft Position Sensor: Service and Repair
CRANKSHAFT POSITION (CKP) SENSOR
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations > Page 3893
Removal and Installation
1. With vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt. 3.
Disconnect the A/C compressor coil electrical connector. 4. Detach the battery cable retainer from
the A/C compressor stud bolts. 5. Remove the nut and detach the A/C tube bracket.
- To install, tighten to 10 Nm (89 lb-in).
6. Remove the stud bolts and position the A/C compressor aside.
- To install, tighten to 25 Nm (18 lb-ft).
7. Disconnect the crankshaft position (CKP) sensor electrical connector. 8. Remove the bolt and
the CKP sensor.
- To install, tighten to 10 Nm (89 lb-in).
9. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service
and Repair
Ignition Cable: Service and Repair
Ignition Components RH Side
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service
and Repair > Page 3897
Ignition Components LH Side
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Specifications
Torque Specifications
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil On Plug (COP) 1
C111
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil On Plug (COP) 1 > Page 3903
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Ignition Coil: Diagrams
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> Page 3917
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 (V8-4.6L (2008))
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> Page 3918
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Page 3919
Ignition Coil: Service and Repair
Ignition Components RH Side
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> Page 3920
Ignition Components LH Side
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Locations
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Locations > Page 3924
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Locations > Page 3925
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1
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Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 3931
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Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 3932
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Camshaft Position Sensor > Component Information > Diagrams > Page 3937
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Page 3938
Camshaft Position Sensor: Service and Repair
CAMSHAFT POSITION (CMP) SENSOR
Removal and Installation
RH side
1. Remove the air cleaner (ACL) outlet pipe.
Both sides
2. Disconnect the camshaft position (CMP) sensor electrical connector. 3. Remove the bolt and the
CMP sensor.
- To install, tighten to 10 Nm (89 lb-in).
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Locations
Crankshaft Position Sensor: Locations
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Crankshaft Position Sensor > Component Information > Locations > Page 3942
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Crankshaft Position Sensor: Diagrams
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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 decelerations between teeth.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Crankshaft Position Sensor > Component Information > Locations > Page 3946
Crankshaft Position Sensor: Service and Repair
CRANKSHAFT POSITION (CKP) SENSOR
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Crankshaft Position Sensor > Component Information > Locations > Page 3947
Removal and Installation
1. With vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt. 3.
Disconnect the A/C compressor coil electrical connector. 4. Detach the battery cable retainer from
the A/C compressor stud bolts. 5. Remove the nut and detach the A/C tube bracket.
- To install, tighten to 10 Nm (89 lb-in).
6. Remove the stud bolts and position the A/C compressor aside.
- To install, tighten to 25 Nm (18 lb-ft).
7. Disconnect the crankshaft position (CKP) sensor electrical connector. 8. Remove the bolt and
the CKP sensor.
- To install, tighten to 10 Nm (89 lb-in).
9. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Part 1
Part 2
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.
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Sensor > Component Information > Locations
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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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > Ignition System - Spark Plug Removal Instructions
Spark Plug: Technical Service Bulletins Ignition System - Spark Plug Removal Instructions
TSB 08-7-6
04/14/08
SPARK PLUG REMOVAL INSTRUCTIONS - 4.6L 3V/5.4L 3V16.8L 3V
FORD: 2005-2008 Mustang 2004-2008 F-150 2005-2008 Expedition, F-Super Duty 2006-2008
Explorer, F-53 Motorhome Chassis 2007-2008 Explorer Sport Trac
LINCOLN: 2005-2008 Navigator 2006-2008 Mark LT
MERCURY: 2006-2008 Mountaineer
This article supersedes TSB 08-1-9 to update Vehicle Applications, Service Procedure and Part
List.
ISSUE Some 2004-2008 F-150, 2006-2008 Mark LT, 2005-2008 F-Super Duty, Expedition, and
Navigator, with 5.4L 3-V engine; 2005-2008 Mustang, 2006-2008 Explorer, Mountaineer, and
2007-2008 Explorer Sport Trac with 4.6L 3-V engine; 2005-2008 F-Super Duty, 2006-2008 and
F-Stripped Chassis, with 6.8L 3-V engine may experience difficulty with spark plug removal. This
may cause damage to the spark plug and leave part of the spark plug in the cylinder head. Affected
engine build dates are as follows: 5.4L 3-V and 6.8L 3-V before 10/9/07, 4.6L 3-V before 11/30/07.
ACTION Refer to the following Service Procedure for techniques to remove the spark plugs and
extract broken spark plugs.
SERVICE PROCEDURE
The engine build date can be read on the left hand cam cover information sticker.
To remove spark plugs without damage, it is necessary to adhere exactly to this procedure before
removal is attempted.
CAUTION
DO NOT REMOVE PLUGS WHEN THE ENGINE IS WARM OR HOT. THE ENGINE MUST BE AT
ROOM TEMPERATURE WHEN PERFORMING SPARK PLUG SERVICE. REMOVING THE
SPARK PLUGS FROM A WARM/HOT ENGINE INCREASES THE CHANCE THE THREADS
COULD BE DAMAGED.
Spark Plug Removal Procedure
1. Remove the coil-on-plug assemblies and thoroughly blow out the spark plug wells and
surrounding valve cover area with compressed air.
2. Back out the spark plugs no more than 1/8 to 1/4 of a turn. Using Motorcraft(R) Carburetor
Tune-Up Cleaner, fill the spark plug well just above where the jamb nut hex sits (1/2 - 3/4
teaspoon). A minimum period of 15 minutes of soak time is required. The cleaner will wick down to
the ground electrode shield and soften the carbon deposits in this time. DO NOT WORK the spark
plug back and forth at this point.
NOTE
COMPLETELY REVIEW THE PRODUCT LABEL FOR THE MOTORCRAFT CARBURETOR
TUNE-UP CLEANER PRODUCT - USE AT ROOM TEMPERATURE AND SHAKE WELL.
CAUTION
EXCESSIVE MOTORCRAFT(R) CARBURETOR TUNE-UP CLEANER, OR REPEATING THE
PROCESS SEVERAL TIMES WITH TOO MUCH CLEANER FLUID, COULD INTRODUCE
ENOUGH LIQUID VOLUME TO HYDRO-LOCK THE ENGINE.
CAUTION
DO NOT USE AIR OR POWER TOOLS FOR SPARK PLUG REMOVAL. SPARK PLUGS MUST
ONLY BE REMOVED WITH HAND TOOLS.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3961
3. Tighten, and then loosen the spark plug, working the plug back and forth. Some screeching and
high effort may be noticed. The expected removal torque is about 33 lb-ft (45 N.m). Repeat the
back and forth turning as needed until turning effort is reduced, and remove the spark plugs.
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP. (Figure 1)
Separated/Broken Spark Plug Removal
If the spark plug separates after following the Spark Plug Removal Procedure, it will fail in one of
three modes. Refer to the appropriate removal procedure as required.
a. Mode 1: The ground electrode shield is left behind as an empty shell. (Figure 2)
b. Mode 2: The entire porcelain insulator and ground electrode shield remains in the cylinder head.
(Figure 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3962
c. Mode 3: The upper section of porcelain broke off with remaining porcelain left inside the ground
shield. (Figure 4)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3963
Flowchart of procedure. (Figure 5)
Mode 1 Procedure:
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3964
Use Rotunda special service tool 303-1203 to remove an empty ground electrode shield from the
cylinder head. (Figure 6)
NOTE
THIS TOOL IS ONLY DESIGNED TO WORK WITH AN EMPTY GROUND ELECTRODE SHIELD.
IF PORCELAIN REMAINS, PROCEED TO MODE 2 OR 3 REMOVAL.
1. Modify vacuum cap to a 3/8" (10 mm) length for each ground electrode shield that needs to be
removed. (Figure 7)
2. Use the installation rod (J) provided with service tool 303-1203 update to install the modified
vacuum cap. Push the cap into the ground shield down to the electrode strap. This will plug and
protect the combustion chamber from contamination. (Figure 7)
3. Thread-tap the ground electrode shield using a 9.0 x 1.0 mm plug tap (tap profile is about 3-4
reduced diameter threads on the tip end).
a. Coat the end of the tap with general purpose grease. (Figure 8)
b. Turn the tap about 3 to 4 turns into the ground electrode shield. Back the tap up frequently to
break chips and avoid cut material from coiling-up in the spark plug well. A tap socket adaptor (K)
is provided with service tool 303-1203 update to connect the tap to a 3/8" socket
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3965
drive.
CAUTION
DO NOT ATTEMPT TO REMOVE THE GROUND ELECTRODE SHIELD WITH THE TAP AND
WRENCH. THE TAP MAY BREAK IF THIS IS ATTEMPTED.
4. Thread Rotunda special service tool 303-1203 into the ground electrode shield. (Figure 9)
a. Install the stepped end of the tool pilot bushing into the spark plug well ensuring it bottoms out.
b. Screw the center shank into the ground electrode shield. Do not over tighten the shank, to
prevent thread stripping.
c. Install the nylon washer and jack nut until finger tight.
d. Turn the jack nut until the ground electrode is freed from the cavity and withdraw the tool
assembly.
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP.
Mode 2 Procedure:
1. Add an additional 1/2 teaspoon Motorcraft® Carburetor Tune-Up Cleaner fluid into spark plug
well and allow 15 minutes of soak time.
2. Using long-reach nose pliers grasp and remove the porcelain with an up and down motion taking
care not to fracture the porcelain.
3. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder
head.
Mode 3 Procedure:
CAUTION
DO NOT DRIVE PORCELAIN DOWN INTO THE GROUND SHIELD WITH A PUNCH AS
FRAGMENTS MAY ENTER THE COMBUSTION CHAMBER.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3966
Use Rotunda special service tool kit 303-1398 to remove porcelain broken inside the ground
electrode shield. (FIGURE 10)
Porcelain Removal - Preparation
CAUTION
THE ENGINE AND THE BONDING ADHESIVE MUST BE ROOM TEMPERATURE OF 70 °F (21
°C) OR HIGHER FOR PROPER CURE AND BOND STRENGTH. VERIFY EXPIRATION DATE OF
ADHESIVE.
CAUTION
DO NOT REUSE PINS. THIS ENSURES THE CORRECT SURFACE CHARACTERISTICS FOR
BONDING.
1. Remove any remaining electrode material from broken porcelain with long nose reach pliers.
2. Spray Motorcraft® Metal Brake Parts Cleaner into the porcelain hole for 2-4 seconds using the
straw nozzle supplied with the brake cleaner can.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3967
3. Insert a pin (A) into the collet (B). Screw the collet onto the threaded rod (C). Install the
assembled collet, pin, and threaded rod into the steel tool pilot (F). (Figures 11 and 12)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3968
4. Retract the collet and pin into the steel tool pilot, protecting the pin. (Figures 13 and 14)
NOTE
PIN TIP DAMAGE OR BENT PINS WILL PREVENT INSERTION INTO THE PORCELAIN.
5. Insert the completed assembly into the spark plug well and fully engage the pin into the
porcelain. (Figure 15)
6. Spray Motorcraft(R) Metal Brake Parts Cleaner 2-4 seconds between the spark plug well and
steel tool pilot. The steel tool pilot must be lifted up approximately 1/2" to allow brake cleaner to
flood the porcelain and pin.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3969
7. Scrub the porcelain inside diameter by moving the threaded rod up and down vigorously. Take
care making sure the pin does not disengage the porcelain. (Figure 16).
8. Repeat Steps 6 and 7.
9. Remove the tool assembly. Again flood the porcelain with Motorcraft(R) Metal Brake Parts
Cleaner for 2-4 seconds, then blow out the entire spark plug well and porcelain with dry
compressed air.
NOTE
CLEAN AND DRY COMPONENTS ARE KEY TO BONDING THE PIN TO THE PORCELAIN.
10. Repeat Steps 1-9 to prepare remaining porcelain fragments as needed.
11. Disassemble the collet and pin from the threaded rod. Dry the tools thoroughly with dry
compressed air.
Porcelain Removal - Bonding Process
CAUTION
USE CARE TO PREVENT BONDING AGENT FROM CONTACTING THREADS IN CYLINDER
HEAD.
NOTE
WORKING TIME LIMIT OF LOCTITE(R) 638(TM) RETAINING COMPOUND IS 5 MINUTES.
1. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to opposite sides of a clean and dry
applicator (H). Excessive amounts of Loctite(R) 638(TM) are being used if it drips off the applicator.
(Figure 17)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3970
2. Insert applicator into the porcelain and move applicator up and down 1/2" (13 mm) while turning
to spread the Loctite® 638TM on the inside of the porcelain. (Figure 18).
3. Add additional Loctite(R) 638(TM), repeating Steps 1 and 2.
4. Clean the applicator with Motorcraft(R) Metal Brake Parts Cleaner before the bonding agent
starts to cure.
5. Reassemble a dry and clean collet and pin assembly.
6. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to the pin. Excessive amounts of
Loctite® 638TMare being used if it drips off the pin.
7. Retract the collet and pin into the steel tool pilot to protect the Loctite(R) 638(TM) coated pin.
8. Insert the completed assembly into spark plug well and fully engage the pin into the porcelain
with a twisting motion to spread the bonding agent.
9. Add additional Loctite® 638TM, repeating Steps 6-8.
10. Leave the pin fully inserted in the porcelain while the adhesive cures. Replace the steel tool
pilot with the aluminum alignment sleeve (G), Figure 9, to support the threaded rod while the
adhesive cures if additional porcelain fragments are present in other cylinders. (Figure 19).
CAUTION
A MINIMUM 1 HOUR CURING TIME AT 70 °F (21 °C) DEGREES IS REQUIRED BEFORE
EXTRACTION IS ATTEMPTED.
11. Allow the Loctite(R) 638(TM) to cure for a minimum of one hour at 70 °F (21 °C).
12. Repeat the bonding process for remaining cylinders as needed.
Porcelain Removal - Extraction
1. After a minimum of one hour curing at 70 °F (21 °C), install the steel pilot tool over the threaded
rod.
2. Install the washer and jack nut until finger tight against the tool pilot bushing.
CAUTION
ONLY THE STEEL PILOT TOOL IS ACCEPTABLE FOR USE IN PORCELAIN REMOVAL.
3. While holding the end of the threaded rod with a wrench, tighten the jack nut until the porcelain is
free of the ground electrode.
4. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder
head.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3971
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP. (FIGURE 7)
Porcelain Removal - Pin Slipped Out
In the unlikely event that the pin does not remove the broken porcelain, this process can be
repeated.
Key elements to success are:
^ Clean and dry porcelain
^ Sufficient Loctite® 638TM Retaining Compound spread uniformly
^ Loctite(R) 638(TM) cure time and temperature
^ Preventing the threaded rod from rotating while removing the porcelain
Replacement Supplies
Replacement kit components and additional kit consumables (Loctite(R) 638TM Retaining
Compound and pins) can be obtained by calling 1-800-ROTUNDA, Option 5.
Parts Block
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
MT080706 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
12405 01
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > General Specifications
Spark Plug: Specifications General Specifications
Item.......................................................................................................................................................
..............................................................Specification
Spark plug gap (not adjustable)............................................................................................................
...................................1.02-1.28 mm (0.040-0.050 in)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > General Specifications > Page 3974
Torque Specifications
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 3975
Spark Plug: Application and ID
Item.......................................................................................................................................................
..............................................................Specification
Spark plug type (early build - black coil boot).......................................................................................
....................................................................PZT-14F Spark plug type (late build - brown coil boot)....
....................................................................................................................................................HJFS
-24FP
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 3976
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.
^
Install new spark plugs.
4. Inspect for normal burning.
^ Check for light tan or gray deposits on the firing tip.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 3977
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(R) 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 a 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.
^ Install new spark plugs.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 3978
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 3979
Spark Plug: Service and Repair
Ignition Components RH Side
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 3980
Ignition Components LH Side
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > 5R55S - Automatic Transaxle/Transmission
Pressure Regulating Solenoid: Specifications 5R55S - Automatic Transaxle/Transmission
Solenoid Operation Chart
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > 5R55S - Automatic Transaxle/Transmission > Page 3988
Pressure Regulating Solenoid: Specifications 6R60 - Automatic Transaxle/Transmission
Solenoid Application Chart
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
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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 3991
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
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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 3992
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
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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 3993
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3994
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3995
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3996
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3997
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3998
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 3999
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4000
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4001
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4002
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 4003
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4004
Pressure Regulating Solenoid: Testing and Inspection
Pinpoint Tests - OSC Equipped Vehicle
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 the following shift solenoid operation information when carrying out Pinpoint Test A.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4005
Solenoid Operation Chart (Part 1)
Solenoid Operation Chart (Part 2)
Shift Solenoid Failure Mode Chart
Failed ON or OFF due to PCM and/or vehicle wiring concerns, solenoid electrically, mechanically
or hydraulically stuck ON or OFF.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4006
SSA, SSB
SSC, SSD
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4007
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 (V8-4.6L (2008))
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 4008
Pressure Regulating Solenoid: Service and Repair
Solenoid Body Assembly
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4009
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid drain plug
and drain the transmission fluid.
3. NOTE: Clean the area around transmission control solenoid body harness connector to prevent
contamination of the transmission control solenoid
body harness connector.
Disconnect the transmission control solenoid body harness connector.
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
reused.
Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan
gasket.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4010
5. Remove the transmission fluid pan filter.
6. CAUTION: Do not damage the solenoid body connector pins.
Remove the transmission control solenoid body screws and remove the transmission control
solenoid body by pulling down on the transmission control solenoid body and pushing down on the
transmission solenoid body connector from the other side of the case.
Installation
1. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the
O-ring seals with clean transmission fluid.
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Information > Diagrams > Page 4011
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 transmission control solenoid body. Tighten the transmission control solenoid body
screws in sequence shown. ^
Tighten to 8 Nm (71 lb-inch).
3. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with
clean transmission fluid.
NOTE: Make sure that the transmission fluid pan filter seals are correctly seated on the
transmission fluid pan filter.
Lubricate the transmission fluid pan seals and install the transmission fluid pan filter. ^
Tighten to 10 Nm (89 lb-inch).
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
reused.
Install the transmission fluid pan and transmission fluid pan gasket and loosely install the
transmission fluid pan screws.
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Information > Diagrams > Page 4012
5. Tighten the transmission fluid pan screws in a crisscross sequence.
^ Tighten to 11 Nm (8 lb-ft).
6. CAUTION: Damage will occur to the transmission control solenoid body assembly if the screw is
tightened above the specification.
NOTE: Always install new O-ring seals on transmission control solenoid body harness connector.
NOTE: Clean the area around transmission control solenoid body harness connector to prevent
contamination of the transmission control solenoid body harness 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 control solenoid body harness connector
and connect the connector. ^
Tighten to 5 Nm (44 lb-inch).
7. Fill the transmission.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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.
2. Disconnect the brake shift interlock actuator electrical connector.
3. Remove the screw and the brake shift interlock actuator.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4016
Installation
1. Install the brake shift interlock actuator.
2. Connect the brake shift interlock actuator electrical connector.
3. Install the front floor console.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > 5R55S - Automatic Transaxle/Transmission
Shift Solenoid: Specifications 5R55S - Automatic Transaxle/Transmission
Solenoid Operation Chart
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > 5R55S - Automatic Transaxle/Transmission > Page 4021
Shift Solenoid: Specifications 6R60 - Automatic Transaxle/Transmission
Solenoid Application Chart
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
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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 4024
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
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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 4025
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
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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 4026
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
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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 4027
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4028
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4029
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4030
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 terminal by pulling each wire at the end of the connector.
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Diagram Information and Instructions > Page 4031
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4032
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
3 = Splice tape
4 = Harness tape
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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 4033
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.
3. lnstall 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 seat wire splice.
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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 4034
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4035
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 4036
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4037
Shift Solenoid: Testing and Inspection
Pinpoint Tests - OSC Equipped Vehicle
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 the following shift solenoid operation information when carrying out Pinpoint Test A.
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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 4038
Solenoid Operation Chart (Part 1)
Solenoid Operation Chart (Part 2)
Shift Solenoid Failure Mode Chart
Failed ON or OFF due to PCM and/or vehicle wiring concerns, solenoid electrically, mechanically
or hydraulically stuck ON or OFF.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Page 4039
SSA, SSB
SSC, SSD
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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 4040
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 (V8-4.6L (2008))
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 4041
Shift Solenoid: Service and Repair
Solenoid Body Assembly
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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 4042
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid drain plug
and drain the transmission fluid.
3. NOTE: Clean the area around transmission control solenoid body harness connector to prevent
contamination of the transmission control solenoid
body harness connector.
Disconnect the transmission control solenoid body harness connector.
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
reused.
Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan
gasket.
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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 4043
5. Remove the transmission fluid pan filter.
6. CAUTION: Do not damage the solenoid body connector pins.
Remove the transmission control solenoid body screws and remove the transmission control
solenoid body by pulling down on the transmission control solenoid body and pushing down on the
transmission solenoid body connector from the other side of the case.
Installation
1. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the
O-ring seals with clean transmission fluid.
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Page 4044
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 transmission control solenoid body. Tighten the transmission control solenoid body
screws in sequence shown. ^
Tighten to 8 Nm (71 lb-inch).
3. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with
clean transmission fluid.
NOTE: Make sure that the transmission fluid pan filter seals are correctly seated on the
transmission fluid pan filter.
Lubricate the transmission fluid pan seals and install the transmission fluid pan filter. ^
Tighten to 10 Nm (89 lb-inch).
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
reused.
Install the transmission fluid pan and transmission fluid pan gasket and loosely install the
transmission fluid pan screws.
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Page 4045
5. Tighten the transmission fluid pan screws in a crisscross sequence.
^ Tighten to 11 Nm (8 lb-ft).
6. CAUTION: Damage will occur to the transmission control solenoid body assembly if the screw is
tightened above the specification.
NOTE: Always install new O-ring seals on transmission control solenoid body harness connector.
NOTE: Clean the area around transmission control solenoid body harness connector to prevent
contamination of the transmission control solenoid body harness 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 control solenoid body harness connector
and connect the connector. ^
Tighten to 5 Nm (44 lb-inch).
7. Fill the transmission.
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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 Application Chart
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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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
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Information > Diagrams > Diagram Information and Instructions > Page 4051
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
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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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
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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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
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Symbols (Part 2)
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Symbols (Part 3)
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Symbols (Part 4)
Symbols (Part 5)
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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 terminal by pulling each wire at the end of the connector.
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Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4059
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4060
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4061
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4062
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 4063
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4064
Torque Converter Clutch Solenoid: Service and Repair
Solenoid Body Assembly
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4065
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid drain plug
and drain the transmission fluid.
3. NOTE: Clean the area around transmission control solenoid body harness connector to prevent
contamination of the transmission control solenoid
body harness connector.
Disconnect the transmission control solenoid body harness connector.
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
reused.
Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan
gasket.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4066
5. Remove the transmission fluid pan filter.
6. CAUTION: Do not damage the solenoid body connector pins.
Remove the transmission control solenoid body screws and remove the transmission control
solenoid body by pulling down on the transmission control solenoid body and pushing down on the
transmission solenoid body connector from the other side of the case.
Installation
1. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the
O-ring seals with clean transmission fluid.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4067
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 transmission control solenoid body. Tighten the transmission control solenoid body
screws in sequence shown. ^
Tighten to 8 Nm (71 lb-inch).
3. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with
clean transmission fluid.
NOTE: Make sure that the transmission fluid pan filter seals are correctly seated on the
transmission fluid pan filter.
Lubricate the transmission fluid pan seals and install the transmission fluid pan filter. ^
Tighten to 10 Nm (89 lb-inch).
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
reused.
Install the transmission fluid pan and transmission fluid pan gasket and loosely install the
transmission fluid pan screws.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4068
5. Tighten the transmission fluid pan screws in a crisscross sequence.
^ Tighten to 11 Nm (8 lb-ft).
6. CAUTION: Damage will occur to the transmission control solenoid body assembly if the screw is
tightened above the specification.
NOTE: Always install new O-ring seals on transmission control solenoid body harness connector.
NOTE: Clean the area around transmission control solenoid body harness connector to prevent
contamination of the transmission control solenoid body harness 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 control solenoid body harness connector
and connect the connector. ^
Tighten to 5 Nm (44 lb-inch).
7. Fill the transmission.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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: > 09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle
Control Module: Customer Interest Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle
TSB 09-22-6
11/16/09
4.6L ENGINE -CHECK ENGINE LIGHT ON - DTC P0196 - COLD WEATHER DRIVING
CONDITIONS- CALIBRATION UPDATE
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
ISSUE Some 2006-2008 Explorer, Mountaineer and Sport Trac vehicles and equipped with 4.6L
3-V engines may exhibit:
^ Diagnostic trouble code (DTC) P0196 - engine oil temperature (EOT) sensor range/performance
during ice/snow driving conditions.
^ Idle speed dropping below specification, hesitation or loss of RPM with no DTCs stored in the
Powertrain Control Module (PCM).
^ Cruise control surge at approximately 50-60 MPH (80-97 Km/h) in hilly regions Only applies to
vehicles operated in altitudes above 5000 feet (1.52
km).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
If normal Powertrain Controls/Emissions Diagnosis (PC/ED) diagnostics do not resolve the above
vehicle concerns, reprogram the PCM and Transmission Control Module (1CM) to the latest
calibration using IDS release 63.08 and higher. This new calibration is not included in the VCM
2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
VEHICLES EQUIPPED WITH A PCM AND TCM, REQUIRE A COORDINATED
REPROGRAMMING.
THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS
OUTLINED BY THE INTERGRATED DIAGNOSTIC SYSTEM (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 63.08 and higher. This new calibration
is not included in the VCM 2009.9 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:
(1) Choose all Tests and Calibrations.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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: > 09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle > Page 4084
(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
DISCONNECTING 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 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. Brake gently to a complete
stop and hold foot on brake for at least 10 seconds.
g. Repeat Steps (e-f) a total of three (3) 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
092206A 2006-2008 Explorer, 1.0 Hr.
Mountaineer 2007-2008 Explorer Sport Trac: Check DTCs, Reprogram The PCM And TCM
Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor
Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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: > 09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle
Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0196/RPM
Loss/Slow Idle
TSB 09-22-6
11/16/09
4.6L ENGINE -CHECK ENGINE LIGHT ON - DTC P0196 - COLD WEATHER DRIVING
CONDITIONS- CALIBRATION UPDATE
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
ISSUE Some 2006-2008 Explorer, Mountaineer and Sport Trac vehicles and equipped with 4.6L
3-V engines may exhibit:
^ Diagnostic trouble code (DTC) P0196 - engine oil temperature (EOT) sensor range/performance
during ice/snow driving conditions.
^ Idle speed dropping below specification, hesitation or loss of RPM with no DTCs stored in the
Powertrain Control Module (PCM).
^ Cruise control surge at approximately 50-60 MPH (80-97 Km/h) in hilly regions Only applies to
vehicles operated in altitudes above 5000 feet (1.52
km).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
If normal Powertrain Controls/Emissions Diagnosis (PC/ED) diagnostics do not resolve the above
vehicle concerns, reprogram the PCM and Transmission Control Module (1CM) to the latest
calibration using IDS release 63.08 and higher. This new calibration is not included in the VCM
2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
VEHICLES EQUIPPED WITH A PCM AND TCM, REQUIRE A COORDINATED
REPROGRAMMING.
THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS
OUTLINED BY THE INTERGRATED DIAGNOSTIC SYSTEM (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 63.08 and higher. This new calibration
is not included in the VCM 2009.9 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:
(1) Choose all Tests and Calibrations.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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: > 09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle > Page
4090
(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
DISCONNECTING 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 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. Brake gently to a complete
stop and hold foot on brake for at least 10 seconds.
g. Repeat Steps (e-f) a total of three (3) 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
092206A 2006-2008 Explorer, 1.0 Hr.
Mountaineer 2007-2008 Explorer Sport Trac: Check DTCs, Reprogram The PCM And TCM
Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor
Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Other Service Bulletins for Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set
Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - Functions
Inoperative/DTC's Set
TSB 09-14-3
07/27/09
SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY
DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED
FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge,
Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid,
Mariner
ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist
and Vehicle Health Report, may exhibit all or most of the following symptoms:
^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface
Module (APIM)
^ SYNC display menus/options blank
^ USB port inoperative
^ No SYNC Blue Tooth device connectivity
^ Voice/Phone/OK steering wheel controls inoperative
^ Lack of APIM communication
^ Parasitic battery draw with APIM connected
These symptoms may be triggered by a low battery state of charge, or a recent battery
disconnect/reconnect.
ACTION Follow the service procedure to correct the condition.
SERVICE PROCEDURE
This software upgrade only applies to the following Accessory Protocol Interface Module (APIM)
Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels:
^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC
^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD
^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD
To determine the current APIM software level, reference the Professional Technician Society (PTS)
website, enter the VIN in OASIS, click the GO
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Other Service Bulletins for Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set >
Page 4096
button and select the SYNC button.
1. Determine if communication can be established with the APIM using IDS.
a. If communication cannot be verified, proceed to Step 2.
b. If communication is present, proceed to Step 3.
2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if
communication can be established. If not, perform
an APIM power reset by disconnecting and reconnecting the vehicle battery.
a. If communication is now present, proceed to Step 3.
b. If communication still cannot be established, replace the APIM.
3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure.
NOTE
SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE
THROUGH THE SYNCMYRIDE.COM WEBSITE.
NOTE
CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS
APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID
AND PASSWORD.
a. Connect the vehicle communication module (VCM) to the data link connector (DLC).
b. Connect the VCM to the IDS tool or laptop running IDS software.
c. Turn the ignition key to the on position.
d. Launch IDS tool.
e. If required, update the VCM with the latest software.
f. Close the IDS tool.
g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle
communication is established, press the GO
button.
h. From the Vehicle Service Session screen, Select the SYNC button.
i. Press read APIM button.
j. Select software and press program APIM to update the SYNC module.
NOTE
YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER
CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP.
NOTE
DO NOT USE A TRANSFER TYPE CABLE.
NOTE
DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING.
NOTE
THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW
THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY
INCLUDED IN WINDOWS XP.
k. Program the processor in the APIM.
l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the
IDS tool or laptop running IDS software, and to the vehicle USB port.
m. Follow the on-screen instructions to program the VIP module.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Other Service Bulletins for Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set >
Page 4097
n. At the end of the configuration and programming procedure, the programming has been
completed successfully screen will be displayed.
o. Exit PTS, disconnect the VCM and disconnect the USB cable.
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
MT091403 Use SLTS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor Performed As Actual Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14D212 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Other Service Bulletins for Control Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality
Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - Poor Cell Phone
Sound Quality
TSB 09-13-5
07/13/09
SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE
RECOGNITION DIFFICULTIES WHILE DRIVING
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009
Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner
ISSUE Some customers of 2008-2009 SYNC equipped vehicles may express concern with their
call sound quality while using the SYNC microphone, complaints of excessive background noise
during a phone call, and/or issues with voice recognition accuracy while driving.
ACTION Follow the service procedure to correct the condition.
SERVICE PROCEDURE
The following service procedure involves updating the Accessory Protocol Interface Module (APIM)
software level and installing an external alternate SYNC microphone attached to the headliner.
NOTE
THIS PROCEDURE DOES NOT APPLY TO DEALER-INSTALLED SYNC SYSTEMS.
Do not perform Step 1 if vehicle is already equipped with SYNC 2.0 (911 and Vehicle Health
Report) or has been upgraded to consumer interface processor (CIP) level 9L3T-14D544-AE. To
determine the current APIM software level, Refer to the Professional Technician Society (PTS)
website, enter the VIN in OASIS, click the GO button, and select the SYNC button.
1. Reprogram the APIM to CIP software level 9L3T-14D544-AE. For additional information Refer to
other SYNC TSB's and WSM, Section 418-01.
Service Pack files may also be obtained at www.syncmyride.com.
When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to
test VR functionality while the vehicle is parked. If customer concerns are still present, this
procedure will not yield an improvement, and the service procedure should not be performed.
Instead, Refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to
assist customer.
The VR experience can be improved with user training and making improvements to the phone
book entries (longer entries make the system more robust). Ensure the customer does not try to
speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce
system effectiveness.
When diagnosing a concern related to call sound quality, expect marginal improvements for calls
described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints
where the call audio seems to drop out intermittently.
NOTE
THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO
THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO
NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING
WITH MICROPHONE INSTALLATION.
2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone
directly to the headliner and splicing in a jumper
harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be
functional.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Other Service Bulletins for Control Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 4102
a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone
installation and wire splicing locations. Refer to
Wiring Diagram (WD), Section 5-1 for recommended splicing methods.
b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or
functionality.
c. The microphone is directional. Make sure the microphone is always positioned so wire length is
minimized from view. When installing the
microphone adjacent to trim, place microphone as close to trim as possible to help minimize visible
wire.
2008-2009 Edge / MKX
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 1)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable up through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124-1 for
links to location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C211. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C210.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
cut wire ends heading up the A-pillar as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2009 Escape / Mariner
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Other Service Bulletins for Control Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 4103
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration (Figures 2 and 3). Firmly
press the microphone into place. Ensure the microphone is parallel and adjacent to overhead
console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an
overhead console. Proceed to Step 5 if not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 501-05 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner to
run microphone cable.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C214. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP41 (BU) and GD182 (BK-GY) from C214.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD1 82 (BK-GY).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
cut wire ends heading up the A-pillar as they are no longer used.
9. Connect the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2008-2009 Navigator / 2009 Expedition
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Other Service Bulletins for Control Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 4104
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figures 4 and 5)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or
positioned directly above A-pillar on headliner if not
equipped with an overhead console.
^ Proceed to Step 5 if not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online
WD, Section 124-1 for links to location and connector
views.
6. Identify circuits VMN07 (GY), RMN07 (VT), and DMN07 (shield - BK) from C298. Cut the three
circuits on the male side of the connector
(17C712 harness).
7. Identify circuits CBP31 (BU-OG) and GD133 (BK) from C298 (2008 Navigator only). Identify
circuits CBP41 (BU) and GD133 (BK) from C298
(2009 Expedition/Navigator only).
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP31 (BU-OG) and any black jumper harness wire to GD133 (BK)
for 2008 Navigator only. Blue jumper harness wire to CBP41 (BU) and any black jumper harness
wire to GD133 (BK) for 2009 Expedition/Navigator only.
^ Ensure original circuits remain connected in splice.
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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 Other Service Bulletins for Control Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 4105
^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07
(VT) and DMN07 (shield - BK).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Connect the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the headliner.
2008-2009 Explorer / Explorer Sport Trac / Mountaineer
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 6)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner run
microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify and cut circuits VMNO7 (GY), RMNO7 (VT), and DMNO7 (shield) from C248. Cut the
three circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP05 (YE) and GD143 (BK-VT) from C248.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP05 (YE) and any black jumper harness wire to GD143 (BK-VT).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07
(VT) and DMN07 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
cut wire ends heading up the A-pillar as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2009 F-150
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Other Service Bulletins for Control Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 4106
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 7)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp.
2. Lower the overhead console or front lamp. Refer to WSM, Section 417-02 for additional
information.
3. Route microphone cable through existing hole in the headliner, and temporarily tuck excess wire
into headliner to the rear of the console or lamp.
4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or
front lamp trim directly behind microphone as
shown.
5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD,
Section 124-1 for links to location and connector
views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C314. Cut the three
circuits on the female side of the connector
(14358 harness).
7. Identify circuits CBP41 (BU) from C315 and GD133 (BK) from C314.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the headliner.
2009 F-Super Duty
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Other Service Bulletins for Control Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 4107
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 8)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
c. This repair is not recommended for vehicles not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield - BK) from C264. Cut the
three circuits on the female side of the connector
(17K745 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C264.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield - BK).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Connect the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2009 Flex
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Other Service Bulletins for Control Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 4108
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 9)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C925. Cut the three
circuits on the female side of the connector (14334 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C925.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2008-2009 Focus
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins >
All Other Service Bulletins for Control Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 4109
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration (Figure 10). Firmly press
the microphone into place. Ensure the microphone is parallel and adjacent to the dome lamp trim.
2. Lower the dome lamp assembly. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable up through existing hole in the headliner, and over to the passenger
side A-pillar. It may be necessary to slightly drop
headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install dome lamp assembly; ensure microphone cable enters the dome lamp trim directly behind
microphone as shown.
5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector
views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C934. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CPL60 (BN-YE) and GD161 (BK-YE) from C934.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CPL60 (BN-YE) and any black jumper harness wire to GD161
(BK-YE).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2008-2009 Fusion / Milan / MKZ
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Other Service Bulletins for Control Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 4110
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 11)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C913. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP02 (GN) and GD139 (BK-YE) from C913.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP02 (GN) and any black jumper harness wire to GD139 (BK-YE).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2008-2009 Taurus / Sable / Taurus X
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 12)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner to
run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Other Service Bulletins for Control Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 4111
5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMN02 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C925. Cut the
three circuits on the female side of the connector
(17K745 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C925.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to
RMN02 (VT-BN) and DMN07 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2009 MKS
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 13)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and out the front of the headliner
above the rear view mirror.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124-1 for
links to location and connector views.
6. Identify circuits VMNO2 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C911. Pull back
the black harness sleeve and cut the three
circuits near C91 1 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2
access cover and cut circuits under trim cover. Refer to WSM, Section 417-01 for additional
information.
7. Identify circuits CBP41 (BU) and GD133 (BK) from C911.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Other Service Bulletins for Control Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 4112
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to
RMN02 (VT-BN) and DMN07 (shield).
^ Only splice into the wires heading away from the connector. The wires heading into the connector
(mirror) are no longer used.
^ Ensure the wiring is neatly routed from the splice locations into the headliner, following the
existing wire harness routing from mirror to headliner.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
OTHER APPLICABLE ARTICLES: 08-21-2
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
MT091305 Claim Diagnosis And Labor Actual
Performed As Actual Time. Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
17700 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Other Service Bulletins for Control Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software
Upgrade
Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - 911 Assist VHR
Software Upgrade
TSB 09-11-8
06/15/09
SYNC WITH 911 ASSIST AND VEHICLE HEALTH REPORT (VHR) DEALER UPGRADE
SOFTWARE
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009
Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner
This article supersedes TSB 9-5-4 to update the Service Procedure and add a production fix date.
ISSUE Some customers with 2008 or 2009 vehicles equipped with SYNC may request the 911
assist and vehicle health report (VHR) service upgrade installation. This software upgrade is not a
warrantable repair. Software is available only through professional technician society (PTS)
website, and not available through the syncmyride.com website.
ACTION Follow the Service Procedure steps to upgrade the SYNC software.
SERVICE PROCEDURE
This software upgrade applies only to the following vehicle model years and build dates:
^ 2008-2009 Focus built before 1/20/2009
^ 2008-2009 Explorer, Explorer Sport Trac, Mountaineer built before 1/12/2009
^ 2008-2009 Edge, MKX, and 2009 Flex, Escape, Mariner built before 12/4/2008
^ 2008-2009 Taurus, Taurus X, Sable, and 2009 F-Super Duty, MKS, F-150 built before 12/1/2008
^ 2008-2009 Fusion, Milan, MKZ
Vehicles built on or after these dates are already equipped with the 911 Assist/Vehicle Health
Report features and do not require updating.
To determine if the vehicles are within these build ranges or have already been upgraded to SYNC
911 Assist/VHR, access the Professional Technician Society (PTS) website, run OASIS by
pressing the Read VIN and DTC's button, and click on the SYNC tab. If the description box
indicates 911 and Vehicle Health Report, vehicle has been upgraded.
The 911 assist with VHR upgrade automatically reprograms the accessory protocol interface
module (APIM), instrument cluster (IC), and restraints control module (RCM).
The VHR applies only to United States (US) vehicles, 911 assist is for US and Canadian vehicles
operated within the US and Canada.
Performing this upgrade may result in some untested devices losing certain functionality, such as
bluetooth connection and phonebook download. Before continuing with this upgrade, make sure
the customer's device is listed on the compatibility matrix. It is strongly recommended to pair the
device to another vehicle currently equipped with 911 Assist/Vehicle Health Report to ensure
proper functionality before continuing.
Configuration and programming requires the use of IDS and a special PTS application. Installer
must have access to PTS and have a valid PTS user ID and password. Ensure the IDS is at the
latest software version.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Other Service Bulletins for Control Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software
Upgrade > Page 4117
For additional programming tips, dealer network setting requirements, and possible error states
related to 911 Assist and VHR upgrades, reference the latest information on the Professional
Technician Society (PTS) website.
1. When updating 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator
vehicles, it is necessary to manually record and
reenter the Oil Life % Value as displayed on the message center. Record the current oil life before
updating 911 Assist/VHR, and reenter using the message center once programming is complete.
2. Connect the vehicle communication module (VCM) to the data link connector (DLC).
3. Connect the VCM to the IDS tool or laptop running IDS software.
4. Turn the ignition key to the on position.
5. Launch IDS tool but do not start a new session.
6. If required, update the VCM with the latest IDS release 59.9 and higher.
7. Close the IDS tool.
8. From the P15 website, run OASIS by pressing the read VIN and DTC's button. After vehicle
communication is established, press the go button.
9. From the Vehicle Service Session screen, select the Upgrade/Mods tab.
10. Once correct vehicle is chosen, select SYNC upgrade with 911 Assist/VHR.
11. Follow the on-screen instructions to program the APIM, IC, and RCM.
NOTE
TO COMPLETE THE UPGRADE PROCESS PERFORM THE FOLLOWING STEPS TO CONFIRM
THE VEHICLE HAS BEEN CORRECTLY CONFIGURED TO HAVE THESE FEATURES. FAILING
TO COMPLETE THE STEPS BELOW MAY RESULT IN 911 ASSIST/VHR NOT DISPLAYING ON
THE SYNC MENU.
12. Set ignition to off.
13. Open and close driver side door.
14. Set ignition to on.
15. Follow applicable instructions (see below) to ensure 911 Assist/VHR appear on Sync menu.
16. Close all Internet Explorer browser windows.
17. Clear all DTC's on all modules.
18. Reenter the Oil Life % Value for 2008-2009 Explorer, Mountaineer, Explorer Sport Trac,
Expedition, or Navigator vehicles.
Navigation Radio Instructions
911 Assist/VHR feature confirmation.
1. Press phone button on the Navigation LCD to enter phone menu.
2. Press cancel when pop-up menu appears on Navigation LCD display.
3. Press settings soft key on Navigation LCD display.
4. Press advanced soft key on Navigation LCD display.
5. Verify 911 Assist/VHR is in menu in Navigation LCD display.
Non Navigation Radio Instructions
911 Assist/VHR feature confirmation.
1. Press phone button on steering wheel.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Other Service Bulletins for Control Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software
Upgrade > Page 4118
2. Press left arrow on steering wheel until return is displayed on radio screen, then press ok.
3. Press left arrow on steering wheel until return is displayed on radio screen, then press ok.
4. Press left arrow until 911 Assist/VHR is displayed.
Once 911 Assist/VHR installation is complete, the customer will need to reload their phone book if
that application is desired.
NOTE
IF SERVICE IS REQUIRED ON 2008 OR 2009 EARLY BUILT VEHICLES UPGRADED TO 911
ASSIST/VHR, REFERENCE THE APPLICABLE 2009 WORKSHOP MANUAL AND FOLLOW THE
V2 DIAGNOSTIC PROCEDURES.
WARRANTY STATUS: Information Only - Not Warrantable
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Other Service Bulletins for Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set >
Page 4124
button and select the SYNC button.
1. Determine if communication can be established with the APIM using IDS.
a. If communication cannot be verified, proceed to Step 2.
b. If communication is present, proceed to Step 3.
2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if
communication can be established. If not, perform
an APIM power reset by disconnecting and reconnecting the vehicle battery.
a. If communication is now present, proceed to Step 3.
b. If communication still cannot be established, replace the APIM.
3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure.
NOTE
SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE
THROUGH THE SYNCMYRIDE.COM WEBSITE.
NOTE
CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS
APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID
AND PASSWORD.
a. Connect the vehicle communication module (VCM) to the data link connector (DLC).
b. Connect the VCM to the IDS tool or laptop running IDS software.
c. Turn the ignition key to the on position.
d. Launch IDS tool.
e. If required, update the VCM with the latest software.
f. Close the IDS tool.
g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle
communication is established, press the GO
button.
h. From the Vehicle Service Session screen, Select the SYNC button.
i. Press read APIM button.
j. Select software and press program APIM to update the SYNC module.
NOTE
YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER
CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP.
NOTE
DO NOT USE A TRANSFER TYPE CABLE.
NOTE
DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING.
NOTE
THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW
THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY
INCLUDED IN WINDOWS XP.
k. Program the processor in the APIM.
l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the
IDS tool or laptop running IDS software, and to the vehicle USB port.
m. Follow the on-screen instructions to program the VIP module.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Other Service Bulletins for Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set >
Page 4125
n. At the end of the configuration and programming procedure, the programming has been
completed successfully screen will be displayed.
o. Exit PTS, disconnect the VCM and disconnect the USB cable.
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
MT091403 Use SLTS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor Performed As Actual Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14D212 04
Disclaimer
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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 Other Service Bulletins for Control Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 4130
a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone
installation and wire splicing locations. Refer to
Wiring Diagram (WD), Section 5-1 for recommended splicing methods.
b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or
functionality.
c. The microphone is directional. Make sure the microphone is always positioned so wire length is
minimized from view. When installing the
microphone adjacent to trim, place microphone as close to trim as possible to help minimize visible
wire.
2008-2009 Edge / MKX
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 1)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable up through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124-1 for
links to location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C211. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C210.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
cut wire ends heading up the A-pillar as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2009 Escape / Mariner
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Other Service Bulletins for Control Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 4131
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration (Figures 2 and 3). Firmly
press the microphone into place. Ensure the microphone is parallel and adjacent to overhead
console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an
overhead console. Proceed to Step 5 if not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 501-05 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner to
run microphone cable.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C214. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP41 (BU) and GD182 (BK-GY) from C214.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD1 82 (BK-GY).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
cut wire ends heading up the A-pillar as they are no longer used.
9. Connect the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2008-2009 Navigator / 2009 Expedition
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Other Service Bulletins for Control Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 4132
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figures 4 and 5)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or
positioned directly above A-pillar on headliner if not
equipped with an overhead console.
^ Proceed to Step 5 if not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online
WD, Section 124-1 for links to location and connector
views.
6. Identify circuits VMN07 (GY), RMN07 (VT), and DMN07 (shield - BK) from C298. Cut the three
circuits on the male side of the connector
(17C712 harness).
7. Identify circuits CBP31 (BU-OG) and GD133 (BK) from C298 (2008 Navigator only). Identify
circuits CBP41 (BU) and GD133 (BK) from C298
(2009 Expedition/Navigator only).
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP31 (BU-OG) and any black jumper harness wire to GD133 (BK)
for 2008 Navigator only. Blue jumper harness wire to CBP41 (BU) and any black jumper harness
wire to GD133 (BK) for 2009 Expedition/Navigator only.
^ Ensure original circuits remain connected in splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Other Service Bulletins for Control Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 4133
^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07
(VT) and DMN07 (shield - BK).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Connect the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the headliner.
2008-2009 Explorer / Explorer Sport Trac / Mountaineer
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 6)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner run
microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify and cut circuits VMNO7 (GY), RMNO7 (VT), and DMNO7 (shield) from C248. Cut the
three circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP05 (YE) and GD143 (BK-VT) from C248.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP05 (YE) and any black jumper harness wire to GD143 (BK-VT).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07
(VT) and DMN07 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
cut wire ends heading up the A-pillar as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2009 F-150
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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 Other Service Bulletins for Control Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 4134
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 7)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp.
2. Lower the overhead console or front lamp. Refer to WSM, Section 417-02 for additional
information.
3. Route microphone cable through existing hole in the headliner, and temporarily tuck excess wire
into headliner to the rear of the console or lamp.
4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or
front lamp trim directly behind microphone as
shown.
5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD,
Section 124-1 for links to location and connector
views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C314. Cut the three
circuits on the female side of the connector
(14358 harness).
7. Identify circuits CBP41 (BU) from C315 and GD133 (BK) from C314.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the headliner.
2009 F-Super Duty
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Other Service Bulletins for Control Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 4135
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 8)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
c. This repair is not recommended for vehicles not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield - BK) from C264. Cut the
three circuits on the female side of the connector
(17K745 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C264.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield - BK).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Connect the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2009 Flex
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Other Service Bulletins for Control Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 4136
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 9)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C925. Cut the three
circuits on the female side of the connector (14334 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C925.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2008-2009 Focus
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins >
All Other Service Bulletins for Control Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 4137
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration (Figure 10). Firmly press
the microphone into place. Ensure the microphone is parallel and adjacent to the dome lamp trim.
2. Lower the dome lamp assembly. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable up through existing hole in the headliner, and over to the passenger
side A-pillar. It may be necessary to slightly drop
headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install dome lamp assembly; ensure microphone cable enters the dome lamp trim directly behind
microphone as shown.
5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector
views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C934. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CPL60 (BN-YE) and GD161 (BK-YE) from C934.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CPL60 (BN-YE) and any black jumper harness wire to GD161
(BK-YE).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2008-2009 Fusion / Milan / MKZ
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Other Service Bulletins for Control Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 4138
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 11)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C913. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP02 (GN) and GD139 (BK-YE) from C913.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP02 (GN) and any black jumper harness wire to GD139 (BK-YE).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2008-2009 Taurus / Sable / Taurus X
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 12)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner to
run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Other Service Bulletins for Control Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 4139
5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMN02 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C925. Cut the
three circuits on the female side of the connector
(17K745 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C925.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to
RMN02 (VT-BN) and DMN07 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2009 MKS
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 13)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and out the front of the headliner
above the rear view mirror.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124-1 for
links to location and connector views.
6. Identify circuits VMNO2 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C911. Pull back
the black harness sleeve and cut the three
circuits near C91 1 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2
access cover and cut circuits under trim cover. Refer to WSM, Section 417-01 for additional
information.
7. Identify circuits CBP41 (BU) and GD133 (BK) from C911.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Other Service Bulletins for Control Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality >
Page 4140
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to
RMN02 (VT-BN) and DMN07 (shield).
^ Only splice into the wires heading away from the connector. The wires heading into the connector
(mirror) are no longer used.
^ Ensure the wiring is neatly routed from the splice locations into the headliner, following the
existing wire harness routing from mirror to headliner.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
OTHER APPLICABLE ARTICLES: 08-21-2
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
MT091305 Claim Diagnosis And Labor Actual
Performed As Actual Time. Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
17700 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Other Service Bulletins for Control Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software
Upgrade > Page 4145
For additional programming tips, dealer network setting requirements, and possible error states
related to 911 Assist and VHR upgrades, reference the latest information on the Professional
Technician Society (PTS) website.
1. When updating 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator
vehicles, it is necessary to manually record and
reenter the Oil Life % Value as displayed on the message center. Record the current oil life before
updating 911 Assist/VHR, and reenter using the message center once programming is complete.
2. Connect the vehicle communication module (VCM) to the data link connector (DLC).
3. Connect the VCM to the IDS tool or laptop running IDS software.
4. Turn the ignition key to the on position.
5. Launch IDS tool but do not start a new session.
6. If required, update the VCM with the latest IDS release 59.9 and higher.
7. Close the IDS tool.
8. From the P15 website, run OASIS by pressing the read VIN and DTC's button. After vehicle
communication is established, press the go button.
9. From the Vehicle Service Session screen, select the Upgrade/Mods tab.
10. Once correct vehicle is chosen, select SYNC upgrade with 911 Assist/VHR.
11. Follow the on-screen instructions to program the APIM, IC, and RCM.
NOTE
TO COMPLETE THE UPGRADE PROCESS PERFORM THE FOLLOWING STEPS TO CONFIRM
THE VEHICLE HAS BEEN CORRECTLY CONFIGURED TO HAVE THESE FEATURES. FAILING
TO COMPLETE THE STEPS BELOW MAY RESULT IN 911 ASSIST/VHR NOT DISPLAYING ON
THE SYNC MENU.
12. Set ignition to off.
13. Open and close driver side door.
14. Set ignition to on.
15. Follow applicable instructions (see below) to ensure 911 Assist/VHR appear on Sync menu.
16. Close all Internet Explorer browser windows.
17. Clear all DTC's on all modules.
18. Reenter the Oil Life % Value for 2008-2009 Explorer, Mountaineer, Explorer Sport Trac,
Expedition, or Navigator vehicles.
Navigation Radio Instructions
911 Assist/VHR feature confirmation.
1. Press phone button on the Navigation LCD to enter phone menu.
2. Press cancel when pop-up menu appears on Navigation LCD display.
3. Press settings soft key on Navigation LCD display.
4. Press advanced soft key on Navigation LCD display.
5. Verify 911 Assist/VHR is in menu in Navigation LCD display.
Non Navigation Radio Instructions
911 Assist/VHR feature confirmation.
1. Press phone button on steering wheel.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Other Service Bulletins for Control Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software
Upgrade > Page 4146
2. Press left arrow on steering wheel until return is displayed on radio screen, then press ok.
3. Press left arrow on steering wheel until return is displayed on radio screen, then press ok.
4. Press left arrow until 911 Assist/VHR is displayed.
Once 911 Assist/VHR installation is complete, the customer will need to reload their phone book if
that application is desired.
NOTE
IF SERVICE IS REQUIRED ON 2008 OR 2009 EARLY BUILT VEHICLES UPGRADED TO 911
ASSIST/VHR, REFERENCE THE APPLICABLE 2009 WORKSHOP MANUAL AND FOLLOW THE
V2 DIAGNOSTIC PROCEDURES.
WARRANTY STATUS: Information Only - Not Warrantable
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 >
Page 4147
View 151-12
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 >
Page 4148
C199
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information >
Diagrams
C2260
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4159
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4160
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4161
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4162
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4163
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4164
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4165
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4166
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4167
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4168
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4169
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4170
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 4171
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4172
Brake Switch - TCC: Description and Operation
BRAKE PEDAL POSITION (BPP) SWITCH
Typical BPP Switch
The BPP switch is sometimes referred to as the 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 antilock 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 (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4177
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4178
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4179
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4180
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4181
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4182
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4183
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4184
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4185
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4186
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4187
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4188
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 4189
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4194
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4195
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4196
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4197
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4198
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4199
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4200
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4201
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4202
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4203
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4204
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4205
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 4206
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 >
Locations
View 151-15
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4212
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4213
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4214
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4215
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4216
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4217
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4218
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4219
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4220
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4221
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4222
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4223
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 4224
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 4227
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 (V8-4.6L (2008))
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 4228
Transmission Mode Switch: Service and Repair
Transmission Control (TC) Switch
Transmission Control (TC) Switch
Removal
1. Remove the selector lever knob. 2. Remove the transmission control (TC) switch from the knob.
Installation
1. Install the TC switch into the selector lever knob. 2. Install the selector lever knob.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Transmission Position Switch/Sensor: Locations
View 151-7
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Page 4232
View 151-11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4235
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4236
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4237
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4238
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4239
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4240
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4241
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4242
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4243
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
3 = Splice tape
4 = Harness tape
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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 4244
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4245
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4246
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 4247
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4248
C167
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4249
Transmission Position Switch/Sensor: Adjustments
Transmission Range (TR) Sensor Adjustment - 5R55S
Adjust
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever 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 digital transmission range (TR) sensor electrical
connector.
4. Disconnect the digital TR sensor electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4250
5. Remove the selector lever cable end from the manual control lever.
6. Remove the outer manual control lever nut and the 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 lb-inch).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4251
9. Install the outer manual lever and nut.
^ Tighten to 48 Nm (35 lb-ft).
10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable
bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable
to make sure that it is locked into the selector lever cable 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 selector lever cable end is correctly installed.
Install the selector lever cable end onto the manual control lever.
11. Reconnect the digital TR sensor electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4252
12. Move the rubber boot back over the TR electrical connector.
13. NOTE: If the selector lever cable shield is loose on the selector lever cable, replace the selector
lever cable shield.
Install the selector lever cable shield.
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 (V8-4.6L (2008))
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 4253
Transmission Position Switch/Sensor: Service and Repair
Digital Transmission Range (TR) Sensor - 5R55S
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by
prying on the side of the selector lever cable shield closest to the boot, then sliding the selector
lever
cable shield away from the boot.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4254
3. Move the rubber boot back to gain access to the digital transmission range (TR) sensor electrical
connector.
4. Disconnect the digital TR sensor electrical connector.
5. Remove the selector lever cable from the manual control lever.
6. Remove the outer manual control lever.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4255
7. Remove the digital TR sensor.
Installation
1. CAUTION: The digital transmission range (TR) 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. ^
Tighten to 8 Nm (71 lb-inch).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4256
3. Install the outer manual lever.
^ Tighten to 48 Nm (35 lb-ft).
4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen
for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that
it is locked into the selector lever cable 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
selector lever cable end is correctly installed.
Install the selector lever cable to the manual control lever.
5. Connect the digital TR sensor electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4257
6. Move the rubber boot back over the TR sensor electrical connector.
7. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector
lever cable shield.
Install the selector lever cable shield.
8. Verify that the selector lever cable is adjusted correctly.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 151-11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4262
Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor
View 151-7
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4263
View 151-11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4264
View 151-11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4267
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4268
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4269
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4270
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4271
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4272
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4273
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4274
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4275
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4276
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4277
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4278
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 4279
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4280
Transmission Speed Sensor: Connector Views
C193
C143
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4281
C164
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S
Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor - 5R55S
Intermediate Shaft Speed Sensor
Intermediate Shaft Speed Sensor
Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
Four wheel drive (4WD) vehicles
2. Disconnect the front driveshaft from the transfer case.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S > Page 4284
3. Disconnect the front driveshaft from the front differential.
4. Remove the front driveshaft from the vehicle.
All vehicles
5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield
closest to the boot, then sliding the selector lever
cable shield away from the boot.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S > Page 4285
6. Remove the selector lever cable and selector lever cable 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S > Page 4286
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.
2 Tighten the intermediate shaft speed sensor screw.
^ Tighten to 14 Nm (10 lb-ft).
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 selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable
bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable
to make sure that it is locked into the selector lever cable 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 selector lever cable end is correctly installed.
Install the selector lever cable and selector lever cable bracket. ^
Tighten to 40 Nm (30 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S > Page 4287
4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector
lever cable shield.
Install the selector lever cable shield.
4WD vehicles
5. Install the front driveshaft in the vehicle.
6. Connect the front driveshaft to the transfer case.
^ Tighten to 30 Nm (22 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S > Page 4288
7. Connect the front driveshaft to the front differential.
^ Tighten to 19 Nm (14 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S > Page 4289
Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor - 5R55S
Output Shaft Speed (OSS) Sensor
Output Shaft Speed (OSS) Sensor
Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
Four wheel drive (4WD) vehicles
2. Disconnect the front driveshaft from the transfer case.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S > Page 4290
3. Disconnect the front driveshaft from the front differential.
4. Remove the front driveshaft from the vehicle.
All vehicles
5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield
closest to the boot, then sliding the selector lever
cable shield away from the boot.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S > Page 4291
6. Remove the selector lever cable and selector lever cable bracket.
7. Disconnect the heated oxygen sensor (HO2S) connector from the transmission case.
8. Disconnect the output shaft speed (OSS) sensor electrical connector.
9. Remove the OSS sensor.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S > Page 4292
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.
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 lb-ft).
2. Connect the OSS sensor electrical connector.
3. Connect the HO2S connector to the transmission case.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S > Page 4293
4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable
bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable
to make sure that it is locked into the selector lever cable 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 selector lever cable end is correctly installed.
Install the selector lever cable and selector lever cable bracket. ^
Tighten to 40 Nm (30 lb-ft).
5. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector
lever cable shield.
Install the selector lever cable shield.
4WD vehicles
6. Install the front driveshaft in the vehicle.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S > Page 4294
7. Connect the front driveshaft to the transfer case.
^ Tighten to 30 Nm (22 lb-ft).
8. Connect the front driveshaft to the front differential.
^ Tighten to 19 Nm (14 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S > Page 4295
Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor - 5R55S
Turbine Shaft Speed (TSS) Sensor
Turbine Shaft Speed (TSS) Sensor
Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
Four wheel drive (4WD) vehicles
2. Disconnect the front driveshaft from the transfer case.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S > Page 4296
3. Disconnect the front driveshaft from the front differential.
4. Remove the front driveshaft from the vehicle.
All vehicles
5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield
closest to the boot, then sliding the selector lever
cable shield away from the boot.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S > Page 4297
6. Remove the selector lever cable and selector lever cable 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S > Page 4298
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.
2 Tighten the TSS sensor screw.
^ Tighten to 14 Nm (10 lb-ft).
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 selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable
bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable
to make sure that it is locked into the selector lever cable 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 selector lever cable end is correctly installed.
Install the selector lever cable and selector lever bracket. ^
Tighten to 40 Nm (30 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S > Page 4299
4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new shield.
Install the selector lever cable shield.
4WD vehicles
5. Install the front driveshaft in the vehicle.
6. Connect the front driveshaft to the transfer case.
^ Tighten to 30 Nm (22 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S > Page 4300
7. Connect the front driveshaft to the front differential.
^ Tighten to 19 Nm (14 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4305
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4306
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4307
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4308
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4309
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4310
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4311
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4312
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4313
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4314
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4315
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4316
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 4317
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC
P0196/RPM Loss/Slow Idle
PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC
P0196/RPM Loss/Slow Idle
TSB 09-22-6
11/16/09
4.6L ENGINE -CHECK ENGINE LIGHT ON - DTC P0196 - COLD WEATHER DRIVING
CONDITIONS- CALIBRATION UPDATE
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
ISSUE Some 2006-2008 Explorer, Mountaineer and Sport Trac vehicles and equipped with 4.6L
3-V engines may exhibit:
^ Diagnostic trouble code (DTC) P0196 - engine oil temperature (EOT) sensor range/performance
during ice/snow driving conditions.
^ Idle speed dropping below specification, hesitation or loss of RPM with no DTCs stored in the
Powertrain Control Module (PCM).
^ Cruise control surge at approximately 50-60 MPH (80-97 Km/h) in hilly regions Only applies to
vehicles operated in altitudes above 5000 feet (1.52
km).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
If normal Powertrain Controls/Emissions Diagnosis (PC/ED) diagnostics do not resolve the above
vehicle concerns, reprogram the PCM and Transmission Control Module (1CM) to the latest
calibration using IDS release 63.08 and higher. This new calibration is not included in the VCM
2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
VEHICLES EQUIPPED WITH A PCM AND TCM, REQUIRE A COORDINATED
REPROGRAMMING.
THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS
OUTLINED BY THE INTERGRATED DIAGNOSTIC SYSTEM (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 63.08 and higher. This new calibration
is not included in the VCM 2009.9 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:
(1) Choose all Tests and Calibrations.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC
P0196/RPM Loss/Slow Idle > Page 4326
(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
DISCONNECTING 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 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. Brake gently to a complete
stop and hold foot on brake for at least 10 seconds.
g. Repeat Steps (e-f) a total of three (3) 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
092206A 2006-2008 Explorer, 1.0 Hr.
Mountaineer 2007-2008 Explorer Sport Trac: Check DTCs, Reprogram The PCM And TCM
Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor
Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 09-1-2 > Jan > 09 > Engine Controls - MIL ON/DTC P0456
Stored In ECM > Page 4331
(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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 09-1-2 > Jan > 09 > Engine Controls - MIL ON/DTC P0456
Stored In ECM > Page 4332
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECALEM 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 08-24-4 > Dec > 08 > A/T, Engine Controls - Low Speed
Driveline Bump > Page 4337
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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 08-24-4 > Dec > 08 > A/T, Engine Controls - Low Speed
Driveline Bump > Page 4338
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 08-13-6 > Jul > 08 > A/T - PCM/TCM Update Required
When Replacing A/T
PROM - Programmable Read Only Memory: Customer Interest A/T - PCM/TCM Update Required
When Replacing A/T
TSB 08-13-6
07/07/08
6R60-6R75 TRANSMISSIONS - REPLACEMENT REQUIREMENTS - JOB 1 ONLY
FORD: 2008 Expedition, Explorer Sport Trac, Explorer
MERCURY: 2008 Mountaineer
ISSUE The 2008 Explorer Sport Trac, Mountaineer, Explorer 4dr vehicles that were built on or
before 11/29/2007 and Expedition vehicles that were built on or before 12/3/2007 were built with a
unique transmission assembly. Only the later (Job-2) transmission design will be available as a
service replacement. The later transmission design has internal changes that are incompatible with
previous calibrations. If transmission replacement is required then a coordinated powertrain control
module (PCM)/ transmission control module (1CM) reprogramming will be necessary to support
these changes of internal hardware.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
The transmission serial number is located on the driver side lower left side behind the manual
lever: Refer to Workshop Manual (WSM), Section 307-01A.
^ Job-1 8L2Z-7000-C will be replaced by Job-2 8L2Z-7000-E (4x2) 6R60
^ Job-1 8L2Z-7000-D will be replaced by Job-2 8L2Z-7000-F (4X4) 6R60
^ Job-1 8L1Z-7000-A will be replaced by Job-2 8LiZ-7000-C (4X2) 6R75
^ Job-1 8L1Z-7000-B will be replaced by Job-2 8LiZ-7000-D (4X4) 6R75
NOTE
VEHICLES THAT HAVE USED THIS PROCEDURE, ANY FUTURE PCM REPLACEMENTS WILL
REQUIRE TRANSMISSION SERIAL NUMBER IDENTIFICATION FOR IDS REPROGRAMMING
SELECTIONS.
Follow Work Shop Manual for Transmission Replacement Procedure.
NOTE
VEHICLES REFERENCED IN THIS ARTICLE ARE EQUIPPED WITH A PCM AND TCM, AND
REQUIRE A COORDINATED FLASH. THIS COORDINATED FLASH 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 FLASH 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 TO ENSURE A PROPER REPAIR.
1. Install IDS/PDS or equivalent and ID the vehicle.
2. Update the PCM/TCM calibration using IDS release 55.11 and higher or 56.1 and higher. This
new calibration is not included in the VCM 2008.7 DVD. Calibration files may also be obtained at
the website. Since the TCM cannot be independently reprogrammed, reprogram the PCM using the
"PMI" function to ensure that engine and transmission calibrations are updated to the latest level
simultaneously. Verify TCM shows correct part number after reprogramming is complete.
3. Clear TCM keep alive memory (KAM) and adaptive tables.
a. Using IDS:
(1) Open Toolbox.
(2) Choose Powertrain.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 08-13-6 > Jul > 08 > A/T - PCM/TCM Update Required
When Replacing A/T > Page 4343
(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 1CM 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.
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 the unit to perform adaptive shift strategy learn.
a. Accelerate from a stop 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 a stop with light throttle ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine
speeds between 1300-1800 RPM.
e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift.
f. Brake gently to a complete stop and hold foot on brake for 10 seconds.
g. Repeat steps (e-f) three (3) 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
081306A 2008 Expedition, Explorer, 1.0 Hr.
Mountaineer, Explorer Sport Trac: Check DTCs, Reprogram PCM/TCM, Includes Time To Clear
TCM KAM, Raise Vehicle To Verify Transmission Serial Number And, Perform Road Test (Do Not
Use With 12650D, 12651D, 12651D4)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 08-13-6 > Jul > 08 > A/T - PCM/TCM Update Required
When Replacing A/T > Page 4344
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 07-23-2 > Nov > 07 > A/T - Delayed
Engagement/Hesitation/Bump on Decel > Page 4353
(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 (V8-4.6L (2008))
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: >
09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL
ON/DTC P0196/RPM Loss/Slow Idle
TSB 09-22-6
11/16/09
4.6L ENGINE -CHECK ENGINE LIGHT ON - DTC P0196 - COLD WEATHER DRIVING
CONDITIONS- CALIBRATION UPDATE
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
ISSUE Some 2006-2008 Explorer, Mountaineer and Sport Trac vehicles and equipped with 4.6L
3-V engines may exhibit:
^ Diagnostic trouble code (DTC) P0196 - engine oil temperature (EOT) sensor range/performance
during ice/snow driving conditions.
^ Idle speed dropping below specification, hesitation or loss of RPM with no DTCs stored in the
Powertrain Control Module (PCM).
^ Cruise control surge at approximately 50-60 MPH (80-97 Km/h) in hilly regions Only applies to
vehicles operated in altitudes above 5000 feet (1.52
km).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
If normal Powertrain Controls/Emissions Diagnosis (PC/ED) diagnostics do not resolve the above
vehicle concerns, reprogram the PCM and Transmission Control Module (1CM) to the latest
calibration using IDS release 63.08 and higher. This new calibration is not included in the VCM
2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
VEHICLES EQUIPPED WITH A PCM AND TCM, REQUIRE A COORDINATED
REPROGRAMMING.
THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS
OUTLINED BY THE INTERGRATED DIAGNOSTIC SYSTEM (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 63.08 and higher. This new calibration
is not included in the VCM 2009.9 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:
(1) Choose all Tests and Calibrations.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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: >
09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle > Page 4359
(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
DISCONNECTING 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 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. Brake gently to a complete
stop and hold foot on brake for at least 10 seconds.
g. Repeat Steps (e-f) a total of three (3) 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
092206A 2006-2008 Explorer, 1.0 Hr.
Mountaineer 2007-2008 Explorer Sport Trac: Check DTCs, Reprogram The PCM And TCM
Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor
Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 4364
(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 (V8-4.6L (2008))
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 4365
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECALEM 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 4370
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
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08-24-4 > Dec > 08 > A/T, Engine Controls - Low Speed Driveline Bump > Page 4371
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
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08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming
PROM - Programmable Read Only Memory: All Technical Service Bulletins Computers/Controls Sync Software Programming
TSB 08-21-2
10/27/08
SYNC SOFTWARE PROGRAMMING SERVICE TIPS
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus 2009 Mustang 2008-2009 Edge, Explorer
Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator 2009 Mark LT
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner
ISSUE The Sync Accessory Protocol Interface Module (APIM) may require updates to add system
enhancements, improve system reliability or address consumer issues. The installation or
availability of these updates may be made available in two different methods:
^ Downloadable consumer Service Pack updates available through www.SYNCmyride.com
website.
^ APIM Programming Using the Integrated Diagnostic System (IDS).
The tool and installation requirements vary between these two methods. This information is being
provided to supplement current publications, clarify the requirements needed to reprogram or
update the APIM module and provide some additional diagnostic/operational system information.
ACTION Refer to the Service Tips for details.
SERVICE TIPS
Downloadable Consumer Service Pack Updates (Available At www.SyncMyRide.com)
These Service Pack Updates are for the Consumer Interface Processor (CIP) side of the APIM
module only and are customized for each vehicle based on the last reported APIM software level
state. The software download process will bundle the appropriate service packs that are required to
achieve the desired state. This is why consumers are asked to report back to the website once they
have completed the install.
NOTE
IT IS NOT RECOMMENDED TO REUSE A DOWNLOADED SERVICE PACK ACROSS
MULTIPLE VEHICLES. EACH DOWNLOAD IS PACKAGED ACCORDINGLY TO THE CURRENT
STATE OF THE VEHICLE THAT THE DOWNLOAD IS INTENDED FOR.
NOTE
CONSUMERS DO NOT HAVE THE ABILITY TO REMOVE SERVICE PACK UPDATES ONCE
THEY ARE INSTALLED.
Steps For Consumer's To Update Sync With The Latest Enhancements
1. Prepare universal serial bus (USB) storage drive by:
a. Log into their Sync account and select applications and updates to download.
b. Locates a portable USB storage drive that they can take to their vehicle.
NOTE
FOR OWNERS OF MULTIPLE SYNC-EQUIPPED VEHICLES, IT IS STRONGLY
RECOMMENDED TO USE A SEPARATE USB DRIVE FOR EACH SYNC-EQUIPPED VEHICLE.
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08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 4376
Dedicating a USB drive to each vehicle's Sync system helps keep each vehicle's download and
installation history current and accurate. In addition, as new Sync features and functionalities
become available, consumers may decide to install different features on different vehicles.
Dedicated USB drives will help maintain the unique applications for each vehicle.
2. Download files by:
a. Plug the USB drive into the computer's USB port.
b. Select the USB port being used on the computer.
c. Confirm choice of USB storage drive. Then click Next.
d. After clicking Next, the files will automatically begin downloading.
NOTE
DO NOT REMOVE THE USB DRIVE UNTIL THE DOWNLOAD IS COMPLETE. THE SCREEN
WILL CONFIRM THAT THE DOWNLOAD IS COMPLETE.
e. Safely remove the USB storage drive from the computer's USB port by clicking on the Windows
personal computer (PC) Safely Remove Hardware icon at the bottom right of the screen, next to
the clock.
3. Install files by:
a. Insert USB storage drive into the vehicle's Sync USB port.
b. Turn on both, the vehicle and radio.
NOTE
IT IS RECOMMENDED TO HAVE THE VEHICLE RUNNING (WITH PROPER EXHAUST
VENTILATION) AND NOT IN THE ACCESSORY MODE. THIS IS TO ENSURE THE VEHICLE'S
BATTERY SUPPLY VOLTAGE REMAINS STABLE DURING THE PROGRAMMING PROCESS.
c. Select User Device.
d. Select Settings.
e. Select Install. Display will change to Begin Installation?
f. Select Yes. Installing file - will display on the screen.
NOTE
DO NOT REMOVE THE USB DRIVE WHILE THE INSTALLATION IS IN PROGRESS.
g. Upon completion of downloading of files, Installation Complete will display on the Sync screen.
h. The Sync voice will say, Installation complete. Sync may also say, The system will now reboot.
Please wait a few moments before using the system. Installation Complete will remain on the Sync
display until you exit the installation mode.
i. Select the Menu radio button to exit installation mode.
j. Remove the USB storage drive.
k. Consumer takes their USB storage drive back to their computer to report the successful install.
(This feature allows for tracking and determining if the consumers vehicle has a newer version
available for downloading or not.)
NOTE
ADDITIONAL INFORMATION AND DETAILS ARE AVAILABLE ON THE SYNCMYRIDE.COM
WEBSITE. REGISTERED SYNC OWNERS WILL SEE VEHICLE SPECIFIC DETAILS AND
DIRECTIONS BASED ON THEIR VEHICLE'S OPTION CONTENT.
APIM Programming Using IDS
This method programs both, the Vehicle Interface Processor (VIP) (through the data link connector)
and CIP (through the USB port), portions of the APIM module.
NOTE
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08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 4377
SOFTWARE PACKAGES OBTAINED THROUGH THE PROFESSIONAL TECHNICIAN SOCIETY
(PTS) WEBSITE CONTAINS BOTH, VIP AND CIP FILES, THESE DO NOT NEED TO BE
INSTALLED IN SEQUENCE LIKE THE CONSUMER DOWNLOAD SERVICE PACK UPDATES,
BUT THE ENTIRE PACKAGE MUST BE INSTALLED DURING REPROGRAMMING FOR
PROPER OPERATION. THESE SOFTWARE PACKAGES ARE MUCH LARGER IN SIZE AND
CONTAIN ALL THE PREVIOUS LEVELS OF ENHANCEMENTS AND UPDATES AS WELL AS
ANY ADDITIONAL ENHANCEMENTS AND UPDATES FOR BOTH THE VIP AND CIP
PROCESSORS LOCATED IN THE APIM MODULE.
NOTE
YOU WILL NOT HAVE THE ABILITY TO RESTORE THE PREVIOUS LEVEL OF SYNC
OPERATING SOFTWARE ONCE THE APIM MODULE HAS BEEN SUCCESSFULLY UPDATED
TO THE NEXT HIGHER LEVEL.
NOTE
If a new APIM is being installed, install the new APIM before carrying out the following procedure.
For additional information, refer to Workshop Manual (WSM), Section 415-00.
It is recommended to install a battery charger to the vehicles battery and set at the low charge
setting and insure the PC being used for reprogramming is fully charged or plugged into a power
source prior to starting the reprogramming process.
1. Turn the ignition key to the On position.
2. Turn the audio control module (ACM) on.
3. Connect the scan tool to the data link connector (DLC).
4. Connect one end of the USB male-A to male-A cable Rotunda part number
CCMUSB2-AM-AM-10 (1-800-Rotunda option 6) or equivalent to the scan tool. Compatible cables.
(Figures 1) Non-compatible cables. (Figure 2)
5. Connect the other end of the USB male-A to male-A cable to the vehicle USB port.
6. From the technician service publication website, run OASIS using Quick Start or by manually
entering the vehicle identification number (VIN).
7. From the OASIS tab, select the Sync/APIM bullet.
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08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 4378
8. Select the Read APIM button to verify the current APIM VIP and CIP software levels.
NOTE
DO NOT DISCONNECT THE VEHICLE COMMUNICATION MODULE (VCM) OR USB CABLES
DURING APIM PROGRAMMING.
9. Select the desired software level from the list of available software for programming then select
the Program APIM button to begin the APIM programming process. Enter the APIM As-Built data if
prompted.
a. When only the CIP is being programmed, select cancel when prompted whether or not to
program the VIP.
b. When the VIP is programmed, the CIP will be programmed automatically.
10. The Sync/APIM application downloads the software into the APIM and displays Programming
has been completed successfully.
11. Test the audio system for correct operation. PC requirements for successful reprogramming an
APIM module.
Ford And LIM Logon Issues - Including Proper Browser Settings
The following list will have you check various computer settings to insure your PC is set to the
proper configuration for reprogramming an APIM module.
NOTE
CHANGES TO PC SETTINGS MAY REQUIRE
ADMINISTRATOR ACCESS.
1. Do not use a customized browser like AOL, it will not work. Please use Internet Explorer (IE)
version 5.5 5P2, 6.0, or higher.
2. Log into website.
3. Navigate to PTS (Professional Technician Society) under the Technical Tools on the Parts and
Service tab.
4. Check IE settings by completing the following:
a. Preliminary Checks.
NOTE
THESE INSTRUCTIONS APPLY TO WINDOWS XP MACHINES WITH 5P2 AND IE 6.0 AND
ABOVE.
(1) Open IE, select Tools at the top of the screen and select Security.
(2) Click on the Internet Zone, and find Navigate Sub-frames across different domains and enable
this function.
(3) Then click OK, system may ask you if you want to accept these function please select Yes.
(4) Check the Windows Firewall to make sure it is turned off by:
(a) Selecting the Start button.
(b) Select Control Panel.
(c) Select Windows Firewall (if you do not see the icon, make sure you are using Classic View) and
set to off.
(5) Check Windows Pop-up Blocker to make sure it is turned off.
(a) Open IE.
(b) Select Tools at the top of the screen.
(c) Select Pop-up Blocker and turn it off.
(6) Remove any add-on toolbars such as Google or Yahoo toolbars, as these have additional built
in pop-up blockers.
(7) Verify that any third party anti-virus, anti-spyware, firewall, or internet security software is
temporarily disabled.
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08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 4379
b. Browser Settings - Open IE and select Internet Options under the Tools heading.
(1) Select the General tab
(2) Select Delete Files and check the Delete all offline content and select OK
(3) Select Delete Cookies and click OK
(4) Select Clear History and select Yes.
(5) Click on the Security tab.
(6) Click on the Trusted Sites icon.
(7) Click on Sites.
(8) In the box below add this website to the zone type in - website.
(9) Ensure that required server verification (https:) for all sites in this zone is not checked.
(10) Click the Add button.
(11) Click the Close button.
(12) Re-select the Security tab and select Custom Level.
(13) Under Reset Custom Settings, pull down and Reset to: Low, select Reset, select Yes and then
OK.
NOTE
IF RUNNING OASIS ON IE 7.0, RESET TO: MEDIUM-LOW. ALSO, UNDER SETTINGS, SCROLL
TO NAVIGATE SUB-FRAMES ACROSS DIFFERENT DOMAINS, SET TO ENABLED AND CLICK
OK.
(14) Select the Privacy tab, and move the slider to Low.
(15) Click on the Advanced, check the box Override automatic cookie handling and check the box
to Always allow session cookies' and
click OK.
(16) Select the Advanced tab and scroll down to HTP 1.1 settings; make sure both options under
this section are checked.
(17) Scroll down to Security section and make sure the following are checked:
(a) Empty Temporary Internet folder when browser is closed.
(b) Use SSL 2.0.
(c) Use SSL 3.0.
(d) Use TLS 1.0.
(e) Select Apply and then click on OK.
5. Close all browsers and reboot the computer to have the browser settings take affect properly.
The browser settings have now been setup correctly as per Ford Browser settings
recommendations.
Additional PC Security Settings (May Or May Not Be Required - Depends On Operating System)
Changes to PC Security Settings may require Administrator access.
1. Check for Information Bar near top of IE page stating - This website wants to run the following
add-ons.
2. Click on Information Bar and select Run ActiveX Controls or Temporarily Allow Pop-ups
depending on your operating system.
3. Click on Retry button to refresh information. (May not be required on some operating systems)
PC and Server Troubleshooting (Optional)
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08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 4380
^ If you wish to test another browser for web-based training only, download the free version of
Opera at www.Opera.com.
^ For web-based training sound problems, make sure your firewall allows downloading sound file
types such as MP3.
^ If you have installed special search and add-on programs such as Gator or Bonzi please remove
them.
^ If you have a router, make sure that port 443 is open for Secure Socket Layer (SSL), and ports
80 and 8080 are open for HTTP.
^ Internet access uses a caching or proxy server. Make sure the caching/proxy servers are set to
automatically detect settings. Contact your local network administrator and/or your Internet service
provider and have them turn off the caching on any and all caching proxy servers for the following:
^ Uniform Resource Locator (URL): www.proservicetech.com or ford website
Additional Sync Related Service Tips
1. Performing a Master Reset of the APIM module or removing and restoring the Keep Alive Power
circuit fuse (refer to the appropriate wiring manual) for 3-minutes, prior to reprogramming will
restore the factory APIM defaults. This can reduce the possibilities of corrupt files, that may have
been transferred into the APIM modules memory, from interfering with the reprogramming of the
CIP portion of the APIM module.
2. Non-factory installed items that can cause background noise, wind noise or obstruct the voice
path to the Sync system's microphone, will reduce the reliability or accuracy of the consumer's
voice commands or speech being recognized properly. Some examples may include but are not
limited to:
^ Objects hanging from the rear view mirror that may make noise or obstruct the system
microphone located on the mirror.
^ Bug shields.
^ Roof mounted accessories.
^ Damaged window moldings.
^ Non-factory installed overhead consoles or sun-visor storage compartments that obstruct the
voice path to the systems microphone. (It is recommended when diagnosing voice recognition or
phone call sound quality issues to eliminate these types of items before replacing any system
components)
3. Remote Starts may prevent the Automatic Discovery Process, of previously paired phones, from
connecting with the consumer's phone as it may be outside of the device's Bluetooth reception
range. Once the vehicle is started remotely, the Sync system automatically begins to search for
previously paired phones; eventually this process will time out if the customers phone does not
enter the vehicle prior to the expiration of this internal timer, resulting in the vehicle Sync not
automatically recognize the phone and pair with it. If this occurs, once the customer enters the
vehicle, the consumer will be required to manually connect the phone through the Sync menus if
they would like to use the hands free phone features.
NOTE
THE CONSUMER WILL NOT BE REQUIRED TO PAIR THE PHONE AGAIN.
4. When Reprogramming APIM modules, it is strongly recommended to use a hard wired internet
connection if possible, due to the APIM program file sizes. If a wired internet connection is not
available, it is recommended to access the PTS website and download the latest Sync software
files from the Tech Central tab prior to reprogramming. This will reduce the overall reprogramming
time when you are connected to the vehicle. If error messages appear during the reprogramming
process that indicate errors with the VIP or CIP file/image, comparing the saved file/image by
checking the file size, between your PC/IDS with the available file/image size indicated in the PTS
description can help determine if the file may be corrupt or damaged. If this has occurred or is
suspected, re-download the file/image and select Yes when asked Do you want to replace it?
5. Always diagnose and repair any DTC's for the Audio system or any module communication
related faults prior to APIM reprogramming.
WARRANTY STATUS: Information Only - Not Warrantable
Disclaimer
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Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
08-13-6 > Jul > 08 > A/T - PCM/TCM Update Required When Replacing A/T
PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T - PCM/TCM
Update Required When Replacing A/T
TSB 08-13-6
07/07/08
6R60-6R75 TRANSMISSIONS - REPLACEMENT REQUIREMENTS - JOB 1 ONLY
FORD: 2008 Expedition, Explorer Sport Trac, Explorer
MERCURY: 2008 Mountaineer
ISSUE The 2008 Explorer Sport Trac, Mountaineer, Explorer 4dr vehicles that were built on or
before 11/29/2007 and Expedition vehicles that were built on or before 12/3/2007 were built with a
unique transmission assembly. Only the later (Job-2) transmission design will be available as a
service replacement. The later transmission design has internal changes that are incompatible with
previous calibrations. If transmission replacement is required then a coordinated powertrain control
module (PCM)/ transmission control module (1CM) reprogramming will be necessary to support
these changes of internal hardware.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
The transmission serial number is located on the driver side lower left side behind the manual
lever: Refer to Workshop Manual (WSM), Section 307-01A.
^ Job-1 8L2Z-7000-C will be replaced by Job-2 8L2Z-7000-E (4x2) 6R60
^ Job-1 8L2Z-7000-D will be replaced by Job-2 8L2Z-7000-F (4X4) 6R60
^ Job-1 8L1Z-7000-A will be replaced by Job-2 8LiZ-7000-C (4X2) 6R75
^ Job-1 8L1Z-7000-B will be replaced by Job-2 8LiZ-7000-D (4X4) 6R75
NOTE
VEHICLES THAT HAVE USED THIS PROCEDURE, ANY FUTURE PCM REPLACEMENTS WILL
REQUIRE TRANSMISSION SERIAL NUMBER IDENTIFICATION FOR IDS REPROGRAMMING
SELECTIONS.
Follow Work Shop Manual for Transmission Replacement Procedure.
NOTE
VEHICLES REFERENCED IN THIS ARTICLE ARE EQUIPPED WITH A PCM AND TCM, AND
REQUIRE A COORDINATED FLASH. THIS COORDINATED FLASH 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 FLASH 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 TO ENSURE A PROPER REPAIR.
1. Install IDS/PDS or equivalent and ID the vehicle.
2. Update the PCM/TCM calibration using IDS release 55.11 and higher or 56.1 and higher. This
new calibration is not included in the VCM 2008.7 DVD. Calibration files may also be obtained at
the website. Since the TCM cannot be independently reprogrammed, reprogram the PCM using the
"PMI" function to ensure that engine and transmission calibrations are updated to the latest level
simultaneously. Verify TCM shows correct part number after reprogramming is complete.
3. Clear TCM keep alive memory (KAM) and adaptive tables.
a. Using IDS:
(1) Open Toolbox.
(2) Choose Powertrain.
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08-13-6 > Jul > 08 > A/T - PCM/TCM Update Required When Replacing A/T > Page 4385
(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 1CM 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.
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 the unit to perform adaptive shift strategy learn.
a. Accelerate from a stop 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 a stop with light throttle ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine
speeds between 1300-1800 RPM.
e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift.
f. Brake gently to a complete stop and hold foot on brake for 10 seconds.
g. Repeat steps (e-f) three (3) 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
081306A 2008 Expedition, Explorer, 1.0 Hr.
Mountaineer, Explorer Sport Trac: Check DTCs, Reprogram PCM/TCM, Includes Time To Clear
TCM KAM, Raise Vehicle To Verify Transmission Serial Number And, Perform Road Test (Do Not
Use With 12650D, 12651D, 12651D4)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
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08-13-6 > Jul > 08 > A/T - PCM/TCM Update Required When Replacing A/T > Page 4386
Disclaimer
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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
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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 (V8-4.6L (2008))
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 4395
(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 (V8-4.6L (2008))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming
PROM - Programmable Read Only Memory: All Technical Service Bulletins Computers/Controls Sync Software Programming
TSB 08-21-2
10/27/08
SYNC SOFTWARE PROGRAMMING SERVICE TIPS
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus 2009 Mustang 2008-2009 Edge, Explorer
Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator 2009 Mark LT
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner
ISSUE The Sync Accessory Protocol Interface Module (APIM) may require updates to add system
enhancements, improve system reliability or address consumer issues. The installation or
availability of these updates may be made available in two different methods:
^ Downloadable consumer Service Pack updates available through www.SYNCmyride.com
website.
^ APIM Programming Using the Integrated Diagnostic System (IDS).
The tool and installation requirements vary between these two methods. This information is being
provided to supplement current publications, clarify the requirements needed to reprogram or
update the APIM module and provide some additional diagnostic/operational system information.
ACTION Refer to the Service Tips for details.
SERVICE TIPS
Downloadable Consumer Service Pack Updates (Available At www.SyncMyRide.com)
These Service Pack Updates are for the Consumer Interface Processor (CIP) side of the APIM
module only and are customized for each vehicle based on the last reported APIM software level
state. The software download process will bundle the appropriate service packs that are required to
achieve the desired state. This is why consumers are asked to report back to the website once they
have completed the install.
NOTE
IT IS NOT RECOMMENDED TO REUSE A DOWNLOADED SERVICE PACK ACROSS
MULTIPLE VEHICLES. EACH DOWNLOAD IS PACKAGED ACCORDINGLY TO THE CURRENT
STATE OF THE VEHICLE THAT THE DOWNLOAD IS INTENDED FOR.
NOTE
CONSUMERS DO NOT HAVE THE ABILITY TO REMOVE SERVICE PACK UPDATES ONCE
THEY ARE INSTALLED.
Steps For Consumer's To Update Sync With The Latest Enhancements
1. Prepare universal serial bus (USB) storage drive by:
a. Log into their Sync account and select applications and updates to download.
b. Locates a portable USB storage drive that they can take to their vehicle.
NOTE
FOR OWNERS OF MULTIPLE SYNC-EQUIPPED VEHICLES, IT IS STRONGLY
RECOMMENDED TO USE A SEPARATE USB DRIVE FOR EACH SYNC-EQUIPPED VEHICLE.
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Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 4401
Dedicating a USB drive to each vehicle's Sync system helps keep each vehicle's download and
installation history current and accurate. In addition, as new Sync features and functionalities
become available, consumers may decide to install different features on different vehicles.
Dedicated USB drives will help maintain the unique applications for each vehicle.
2. Download files by:
a. Plug the USB drive into the computer's USB port.
b. Select the USB port being used on the computer.
c. Confirm choice of USB storage drive. Then click Next.
d. After clicking Next, the files will automatically begin downloading.
NOTE
DO NOT REMOVE THE USB DRIVE UNTIL THE DOWNLOAD IS COMPLETE. THE SCREEN
WILL CONFIRM THAT THE DOWNLOAD IS COMPLETE.
e. Safely remove the USB storage drive from the computer's USB port by clicking on the Windows
personal computer (PC) Safely Remove Hardware icon at the bottom right of the screen, next to
the clock.
3. Install files by:
a. Insert USB storage drive into the vehicle's Sync USB port.
b. Turn on both, the vehicle and radio.
NOTE
IT IS RECOMMENDED TO HAVE THE VEHICLE RUNNING (WITH PROPER EXHAUST
VENTILATION) AND NOT IN THE ACCESSORY MODE. THIS IS TO ENSURE THE VEHICLE'S
BATTERY SUPPLY VOLTAGE REMAINS STABLE DURING THE PROGRAMMING PROCESS.
c. Select User Device.
d. Select Settings.
e. Select Install. Display will change to Begin Installation?
f. Select Yes. Installing file - will display on the screen.
NOTE
DO NOT REMOVE THE USB DRIVE WHILE THE INSTALLATION IS IN PROGRESS.
g. Upon completion of downloading of files, Installation Complete will display on the Sync screen.
h. The Sync voice will say, Installation complete. Sync may also say, The system will now reboot.
Please wait a few moments before using the system. Installation Complete will remain on the Sync
display until you exit the installation mode.
i. Select the Menu radio button to exit installation mode.
j. Remove the USB storage drive.
k. Consumer takes their USB storage drive back to their computer to report the successful install.
(This feature allows for tracking and determining if the consumers vehicle has a newer version
available for downloading or not.)
NOTE
ADDITIONAL INFORMATION AND DETAILS ARE AVAILABLE ON THE SYNCMYRIDE.COM
WEBSITE. REGISTERED SYNC OWNERS WILL SEE VEHICLE SPECIFIC DETAILS AND
DIRECTIONS BASED ON THEIR VEHICLE'S OPTION CONTENT.
APIM Programming Using IDS
This method programs both, the Vehicle Interface Processor (VIP) (through the data link connector)
and CIP (through the USB port), portions of the APIM module.
NOTE
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Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 4402
SOFTWARE PACKAGES OBTAINED THROUGH THE PROFESSIONAL TECHNICIAN SOCIETY
(PTS) WEBSITE CONTAINS BOTH, VIP AND CIP FILES, THESE DO NOT NEED TO BE
INSTALLED IN SEQUENCE LIKE THE CONSUMER DOWNLOAD SERVICE PACK UPDATES,
BUT THE ENTIRE PACKAGE MUST BE INSTALLED DURING REPROGRAMMING FOR
PROPER OPERATION. THESE SOFTWARE PACKAGES ARE MUCH LARGER IN SIZE AND
CONTAIN ALL THE PREVIOUS LEVELS OF ENHANCEMENTS AND UPDATES AS WELL AS
ANY ADDITIONAL ENHANCEMENTS AND UPDATES FOR BOTH THE VIP AND CIP
PROCESSORS LOCATED IN THE APIM MODULE.
NOTE
YOU WILL NOT HAVE THE ABILITY TO RESTORE THE PREVIOUS LEVEL OF SYNC
OPERATING SOFTWARE ONCE THE APIM MODULE HAS BEEN SUCCESSFULLY UPDATED
TO THE NEXT HIGHER LEVEL.
NOTE
If a new APIM is being installed, install the new APIM before carrying out the following procedure.
For additional information, refer to Workshop Manual (WSM), Section 415-00.
It is recommended to install a battery charger to the vehicles battery and set at the low charge
setting and insure the PC being used for reprogramming is fully charged or plugged into a power
source prior to starting the reprogramming process.
1. Turn the ignition key to the On position.
2. Turn the audio control module (ACM) on.
3. Connect the scan tool to the data link connector (DLC).
4. Connect one end of the USB male-A to male-A cable Rotunda part number
CCMUSB2-AM-AM-10 (1-800-Rotunda option 6) or equivalent to the scan tool. Compatible cables.
(Figures 1) Non-compatible cables. (Figure 2)
5. Connect the other end of the USB male-A to male-A cable to the vehicle USB port.
6. From the technician service publication website, run OASIS using Quick Start or by manually
entering the vehicle identification number (VIN).
7. From the OASIS tab, select the Sync/APIM bullet.
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Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 4403
8. Select the Read APIM button to verify the current APIM VIP and CIP software levels.
NOTE
DO NOT DISCONNECT THE VEHICLE COMMUNICATION MODULE (VCM) OR USB CABLES
DURING APIM PROGRAMMING.
9. Select the desired software level from the list of available software for programming then select
the Program APIM button to begin the APIM programming process. Enter the APIM As-Built data if
prompted.
a. When only the CIP is being programmed, select cancel when prompted whether or not to
program the VIP.
b. When the VIP is programmed, the CIP will be programmed automatically.
10. The Sync/APIM application downloads the software into the APIM and displays Programming
has been completed successfully.
11. Test the audio system for correct operation. PC requirements for successful reprogramming an
APIM module.
Ford And LIM Logon Issues - Including Proper Browser Settings
The following list will have you check various computer settings to insure your PC is set to the
proper configuration for reprogramming an APIM module.
NOTE
CHANGES TO PC SETTINGS MAY REQUIRE
ADMINISTRATOR ACCESS.
1. Do not use a customized browser like AOL, it will not work. Please use Internet Explorer (IE)
version 5.5 5P2, 6.0, or higher.
2. Log into website.
3. Navigate to PTS (Professional Technician Society) under the Technical Tools on the Parts and
Service tab.
4. Check IE settings by completing the following:
a. Preliminary Checks.
NOTE
THESE INSTRUCTIONS APPLY TO WINDOWS XP MACHINES WITH 5P2 AND IE 6.0 AND
ABOVE.
(1) Open IE, select Tools at the top of the screen and select Security.
(2) Click on the Internet Zone, and find Navigate Sub-frames across different domains and enable
this function.
(3) Then click OK, system may ask you if you want to accept these function please select Yes.
(4) Check the Windows Firewall to make sure it is turned off by:
(a) Selecting the Start button.
(b) Select Control Panel.
(c) Select Windows Firewall (if you do not see the icon, make sure you are using Classic View) and
set to off.
(5) Check Windows Pop-up Blocker to make sure it is turned off.
(a) Open IE.
(b) Select Tools at the top of the screen.
(c) Select Pop-up Blocker and turn it off.
(6) Remove any add-on toolbars such as Google or Yahoo toolbars, as these have additional built
in pop-up blockers.
(7) Verify that any third party anti-virus, anti-spyware, firewall, or internet security software is
temporarily disabled.
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08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 4404
b. Browser Settings - Open IE and select Internet Options under the Tools heading.
(1) Select the General tab
(2) Select Delete Files and check the Delete all offline content and select OK
(3) Select Delete Cookies and click OK
(4) Select Clear History and select Yes.
(5) Click on the Security tab.
(6) Click on the Trusted Sites icon.
(7) Click on Sites.
(8) In the box below add this website to the zone type in - website.
(9) Ensure that required server verification (https:) for all sites in this zone is not checked.
(10) Click the Add button.
(11) Click the Close button.
(12) Re-select the Security tab and select Custom Level.
(13) Under Reset Custom Settings, pull down and Reset to: Low, select Reset, select Yes and then
OK.
NOTE
IF RUNNING OASIS ON IE 7.0, RESET TO: MEDIUM-LOW. ALSO, UNDER SETTINGS, SCROLL
TO NAVIGATE SUB-FRAMES ACROSS DIFFERENT DOMAINS, SET TO ENABLED AND CLICK
OK.
(14) Select the Privacy tab, and move the slider to Low.
(15) Click on the Advanced, check the box Override automatic cookie handling and check the box
to Always allow session cookies' and
click OK.
(16) Select the Advanced tab and scroll down to HTP 1.1 settings; make sure both options under
this section are checked.
(17) Scroll down to Security section and make sure the following are checked:
(a) Empty Temporary Internet folder when browser is closed.
(b) Use SSL 2.0.
(c) Use SSL 3.0.
(d) Use TLS 1.0.
(e) Select Apply and then click on OK.
5. Close all browsers and reboot the computer to have the browser settings take affect properly.
The browser settings have now been setup correctly as per Ford Browser settings
recommendations.
Additional PC Security Settings (May Or May Not Be Required - Depends On Operating System)
Changes to PC Security Settings may require Administrator access.
1. Check for Information Bar near top of IE page stating - This website wants to run the following
add-ons.
2. Click on Information Bar and select Run ActiveX Controls or Temporarily Allow Pop-ups
depending on your operating system.
3. Click on Retry button to refresh information. (May not be required on some operating systems)
PC and Server Troubleshooting (Optional)
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Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 4405
^ If you wish to test another browser for web-based training only, download the free version of
Opera at www.Opera.com.
^ For web-based training sound problems, make sure your firewall allows downloading sound file
types such as MP3.
^ If you have installed special search and add-on programs such as Gator or Bonzi please remove
them.
^ If you have a router, make sure that port 443 is open for Secure Socket Layer (SSL), and ports
80 and 8080 are open for HTTP.
^ Internet access uses a caching or proxy server. Make sure the caching/proxy servers are set to
automatically detect settings. Contact your local network administrator and/or your Internet service
provider and have them turn off the caching on any and all caching proxy servers for the following:
^ Uniform Resource Locator (URL): www.proservicetech.com or ford website
Additional Sync Related Service Tips
1. Performing a Master Reset of the APIM module or removing and restoring the Keep Alive Power
circuit fuse (refer to the appropriate wiring manual) for 3-minutes, prior to reprogramming will
restore the factory APIM defaults. This can reduce the possibilities of corrupt files, that may have
been transferred into the APIM modules memory, from interfering with the reprogramming of the
CIP portion of the APIM module.
2. Non-factory installed items that can cause background noise, wind noise or obstruct the voice
path to the Sync system's microphone, will reduce the reliability or accuracy of the consumer's
voice commands or speech being recognized properly. Some examples may include but are not
limited to:
^ Objects hanging from the rear view mirror that may make noise or obstruct the system
microphone located on the mirror.
^ Bug shields.
^ Roof mounted accessories.
^ Damaged window moldings.
^ Non-factory installed overhead consoles or sun-visor storage compartments that obstruct the
voice path to the systems microphone. (It is recommended when diagnosing voice recognition or
phone call sound quality issues to eliminate these types of items before replacing any system
components)
3. Remote Starts may prevent the Automatic Discovery Process, of previously paired phones, from
connecting with the consumer's phone as it may be outside of the device's Bluetooth reception
range. Once the vehicle is started remotely, the Sync system automatically begins to search for
previously paired phones; eventually this process will time out if the customers phone does not
enter the vehicle prior to the expiration of this internal timer, resulting in the vehicle Sync not
automatically recognize the phone and pair with it. If this occurs, once the customer enters the
vehicle, the consumer will be required to manually connect the phone through the Sync menus if
they would like to use the hands free phone features.
NOTE
THE CONSUMER WILL NOT BE REQUIRED TO PAIR THE PHONE AGAIN.
4. When Reprogramming APIM modules, it is strongly recommended to use a hard wired internet
connection if possible, due to the APIM program file sizes. If a wired internet connection is not
available, it is recommended to access the PTS website and download the latest Sync software
files from the Tech Central tab prior to reprogramming. This will reduce the overall reprogramming
time when you are connected to the vehicle. If error messages appear during the reprogramming
process that indicate errors with the VIP or CIP file/image, comparing the saved file/image by
checking the file size, between your PC/IDS with the available file/image size indicated in the PTS
description can help determine if the file may be corrupt or damaged. If this has occurred or is
suspected, re-download the file/image and select Yes when asked Do you want to replace it?
5. Always diagnose and repair any DTC's for the Audio system or any module communication
related faults prior to APIM reprogramming.
WARRANTY STATUS: Information Only - Not Warrantable
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > 5R55S Automatic Transaxle/Transmission
Pressure Regulating Solenoid: Specifications 5R55S - Automatic Transaxle/Transmission
Solenoid Operation Chart
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Pressure Regulating Solenoid: Specifications 6R60 - Automatic Transaxle/Transmission
Solenoid Application Chart
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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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
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Information and Instructions > Page 4416
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
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Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 4417
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
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Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 4418
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
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Symbols (Part 2)
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Symbols (Part 3)
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Information and Instructions > Page 4421
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4422
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4423
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4424
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4425
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4426
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4427
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 4428
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4429
Pressure Regulating Solenoid: Testing and Inspection
Pinpoint Tests - OSC Equipped Vehicle
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 the following shift solenoid operation information when carrying out Pinpoint Test A.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4430
Solenoid Operation Chart (Part 1)
Solenoid Operation Chart (Part 2)
Shift Solenoid Failure Mode Chart
Failed ON or OFF due to PCM and/or vehicle wiring concerns, solenoid electrically, mechanically
or hydraulically stuck ON or OFF.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4431
SSA, SSB
SSC, SSD
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4432
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 (V8-4.6L (2008))
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 4433
Pressure Regulating Solenoid: Service and Repair
Solenoid Body Assembly
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4434
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid drain plug
and drain the transmission fluid.
3. NOTE: Clean the area around transmission control solenoid body harness connector to prevent
contamination of the transmission control solenoid
body harness connector.
Disconnect the transmission control solenoid body harness connector.
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
reused.
Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan
gasket.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4435
5. Remove the transmission fluid pan filter.
6. CAUTION: Do not damage the solenoid body connector pins.
Remove the transmission control solenoid body screws and remove the transmission control
solenoid body by pulling down on the transmission control solenoid body and pushing down on the
transmission solenoid body connector from the other side of the case.
Installation
1. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the
O-ring seals with clean transmission fluid.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4436
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 transmission control solenoid body. Tighten the transmission control solenoid body
screws in sequence shown. ^
Tighten to 8 Nm (71 lb-inch).
3. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with
clean transmission fluid.
NOTE: Make sure that the transmission fluid pan filter seals are correctly seated on the
transmission fluid pan filter.
Lubricate the transmission fluid pan seals and install the transmission fluid pan filter. ^
Tighten to 10 Nm (89 lb-inch).
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
reused.
Install the transmission fluid pan and transmission fluid pan gasket and loosely install the
transmission fluid pan screws.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4437
5. Tighten the transmission fluid pan screws in a crisscross sequence.
^ Tighten to 11 Nm (8 lb-ft).
6. CAUTION: Damage will occur to the transmission control solenoid body assembly if the screw is
tightened above the specification.
NOTE: Always install new O-ring seals on transmission control solenoid body harness connector.
NOTE: Clean the area around transmission control solenoid body harness connector to prevent
contamination of the transmission control solenoid body harness 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 control solenoid body harness connector
and connect the connector. ^
Tighten to 5 Nm (44 lb-inch).
7. Fill the transmission.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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.
2. Disconnect the brake shift interlock actuator electrical connector.
3. Remove the screw and the brake shift interlock actuator.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4441
Installation
1. Install the brake shift interlock actuator.
2. Connect the brake shift interlock actuator electrical connector.
3. Install the front floor console.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > 5R55S - Automatic
Transaxle/Transmission
Shift Solenoid: Specifications 5R55S - Automatic Transaxle/Transmission
Solenoid Operation Chart
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > 5R55S - Automatic
Transaxle/Transmission > Page 4446
Shift Solenoid: Specifications 6R60 - Automatic Transaxle/Transmission
Solenoid Application Chart
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4449
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4450
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4451
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4452
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4453
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4454
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4455
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4456
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4457
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4458
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4459
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4460
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 4461
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4462
Shift Solenoid: Testing and Inspection
Pinpoint Tests - OSC Equipped Vehicle
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 the following shift solenoid operation information when carrying out Pinpoint Test A.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4463
Solenoid Operation Chart (Part 1)
Solenoid Operation Chart (Part 2)
Shift Solenoid Failure Mode Chart
Failed ON or OFF due to PCM and/or vehicle wiring concerns, solenoid electrically, mechanically
or hydraulically stuck ON or OFF.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4464
SSA, SSB
SSC, SSD
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4465
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 (V8-4.6L (2008))
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 4466
Shift Solenoid: Service and Repair
Solenoid Body Assembly
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4467
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid drain plug
and drain the transmission fluid.
3. NOTE: Clean the area around transmission control solenoid body harness connector to prevent
contamination of the transmission control solenoid
body harness connector.
Disconnect the transmission control solenoid body harness connector.
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
reused.
Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan
gasket.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4468
5. Remove the transmission fluid pan filter.
6. CAUTION: Do not damage the solenoid body connector pins.
Remove the transmission control solenoid body screws and remove the transmission control
solenoid body by pulling down on the transmission control solenoid body and pushing down on the
transmission solenoid body connector from the other side of the case.
Installation
1. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the
O-ring seals with clean transmission fluid.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4469
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 transmission control solenoid body. Tighten the transmission control solenoid body
screws in sequence shown. ^
Tighten to 8 Nm (71 lb-inch).
3. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with
clean transmission fluid.
NOTE: Make sure that the transmission fluid pan filter seals are correctly seated on the
transmission fluid pan filter.
Lubricate the transmission fluid pan seals and install the transmission fluid pan filter. ^
Tighten to 10 Nm (89 lb-inch).
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
reused.
Install the transmission fluid pan and transmission fluid pan gasket and loosely install the
transmission fluid pan screws.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4470
5. Tighten the transmission fluid pan screws in a crisscross sequence.
^ Tighten to 11 Nm (8 lb-ft).
6. CAUTION: Damage will occur to the transmission control solenoid body assembly if the screw is
tightened above the specification.
NOTE: Always install new O-ring seals on transmission control solenoid body harness connector.
NOTE: Clean the area around transmission control solenoid body harness connector to prevent
contamination of the transmission control solenoid body harness 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 control solenoid body harness connector
and connect the connector. ^
Tighten to 5 Nm (44 lb-inch).
7. Fill the transmission.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Application Chart
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4476
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4477
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4478
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4479
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4480
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4481
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4482
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4483
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4484
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4485
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4486
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4487
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 4488
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4489
Torque Converter Clutch Solenoid: Service and Repair
Solenoid Body Assembly
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4490
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid drain plug
and drain the transmission fluid.
3. NOTE: Clean the area around transmission control solenoid body harness connector to prevent
contamination of the transmission control solenoid
body harness connector.
Disconnect the transmission control solenoid body harness connector.
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
reused.
Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan
gasket.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4491
5. Remove the transmission fluid pan filter.
6. CAUTION: Do not damage the solenoid body connector pins.
Remove the transmission control solenoid body screws and remove the transmission control
solenoid body by pulling down on the transmission control solenoid body and pushing down on the
transmission solenoid body connector from the other side of the case.
Installation
1. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the
O-ring seals with clean transmission fluid.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4492
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 transmission control solenoid body. Tighten the transmission control solenoid body
screws in sequence shown. ^
Tighten to 8 Nm (71 lb-inch).
3. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with
clean transmission fluid.
NOTE: Make sure that the transmission fluid pan filter seals are correctly seated on the
transmission fluid pan filter.
Lubricate the transmission fluid pan seals and install the transmission fluid pan filter. ^
Tighten to 10 Nm (89 lb-inch).
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
reused.
Install the transmission fluid pan and transmission fluid pan gasket and loosely install the
transmission fluid pan screws.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4493
5. Tighten the transmission fluid pan screws in a crisscross sequence.
^ Tighten to 11 Nm (8 lb-ft).
6. CAUTION: Damage will occur to the transmission control solenoid body assembly if the screw is
tightened above the specification.
NOTE: Always install new O-ring seals on transmission control solenoid body harness connector.
NOTE: Clean the area around transmission control solenoid body harness connector to prevent
contamination of the transmission control solenoid body harness 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 control solenoid body harness connector
and connect the connector. ^
Tighten to 5 Nm (44 lb-inch).
7. Fill the transmission.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Specifications > 5R55S - Automatic
Transaxle/Transmission
Pressure Regulating Solenoid: Specifications 5R55S - Automatic Transaxle/Transmission
Solenoid Operation Chart
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Specifications > 5R55S - Automatic
Transaxle/Transmission > Page 4500
Pressure Regulating Solenoid: Specifications 6R60 - Automatic Transaxle/Transmission
Solenoid Application Chart
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4503
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4504
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4505
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4506
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4507
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4508
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4509
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4510
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4511
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4512
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4513
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4514
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4516
Pressure Regulating Solenoid: Testing and Inspection
Pinpoint Tests - OSC Equipped Vehicle
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 the following shift solenoid operation information when carrying out Pinpoint Test A.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4517
Solenoid Operation Chart (Part 1)
Solenoid Operation Chart (Part 2)
Shift Solenoid Failure Mode Chart
Failed ON or OFF due to PCM and/or vehicle wiring concerns, solenoid electrically, mechanically
or hydraulically stuck ON or OFF.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4518
SSA, SSB
SSC, SSD
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4519
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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4520
Pressure Regulating Solenoid: Service and Repair
Solenoid Body Assembly
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4521
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid drain plug
and drain the transmission fluid.
3. NOTE: Clean the area around transmission control solenoid body harness connector to prevent
contamination of the transmission control solenoid
body harness connector.
Disconnect the transmission control solenoid body harness connector.
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
reused.
Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan
gasket.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4522
5. Remove the transmission fluid pan filter.
6. CAUTION: Do not damage the solenoid body connector pins.
Remove the transmission control solenoid body screws and remove the transmission control
solenoid body by pulling down on the transmission control solenoid body and pushing down on the
transmission solenoid body connector from the other side of the case.
Installation
1. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the
O-ring seals with clean transmission fluid.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4523
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 transmission control solenoid body. Tighten the transmission control solenoid body
screws in sequence shown. ^
Tighten to 8 Nm (71 lb-inch).
3. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with
clean transmission fluid.
NOTE: Make sure that the transmission fluid pan filter seals are correctly seated on the
transmission fluid pan filter.
Lubricate the transmission fluid pan seals and install the transmission fluid pan filter. ^
Tighten to 10 Nm (89 lb-inch).
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
reused.
Install the transmission fluid pan and transmission fluid pan gasket and loosely install the
transmission fluid pan screws.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 4524
5. Tighten the transmission fluid pan screws in a crisscross sequence.
^ Tighten to 11 Nm (8 lb-ft).
6. CAUTION: Damage will occur to the transmission control solenoid body assembly if the screw is
tightened above the specification.
NOTE: Always install new O-ring seals on transmission control solenoid body harness connector.
NOTE: Clean the area around transmission control solenoid body harness connector to prevent
contamination of the transmission control solenoid body harness 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 control solenoid body harness connector
and connect the connector. ^
Tighten to 5 Nm (44 lb-inch).
7. Fill the transmission.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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.
2. Disconnect the brake shift interlock actuator electrical connector.
3. Remove the screw and the brake shift interlock actuator.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 4528
Installation
1. Install the brake shift interlock actuator.
2. Connect the brake shift interlock actuator electrical connector.
3. Install the front floor console.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Specifications > 5R55S - Automatic Transaxle/Transmission
Shift Solenoid: Specifications 5R55S - Automatic Transaxle/Transmission
Solenoid Operation Chart
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Specifications > 5R55S - Automatic Transaxle/Transmission > Page
4533
Shift Solenoid: Specifications 6R60 - Automatic Transaxle/Transmission
Solenoid Application Chart
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4536
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4537
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4538
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4539
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4540
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4541
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4542
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4543
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4544
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4545
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4546
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4547
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 4548
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4549
Shift Solenoid: Testing and Inspection
Pinpoint Tests - OSC Equipped Vehicle
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 the following shift solenoid operation information when carrying out Pinpoint Test A.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4550
Solenoid Operation Chart (Part 1)
Solenoid Operation Chart (Part 2)
Shift Solenoid Failure Mode Chart
Failed ON or OFF due to PCM and/or vehicle wiring concerns, solenoid electrically, mechanically
or hydraulically stuck ON or OFF.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4551
SSA, SSB
SSC, SSD
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4552
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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4553
Shift Solenoid: Service and Repair
Solenoid Body Assembly
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4554
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid drain plug
and drain the transmission fluid.
3. NOTE: Clean the area around transmission control solenoid body harness connector to prevent
contamination of the transmission control solenoid
body harness connector.
Disconnect the transmission control solenoid body harness connector.
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
reused.
Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan
gasket.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4555
5. Remove the transmission fluid pan filter.
6. CAUTION: Do not damage the solenoid body connector pins.
Remove the transmission control solenoid body screws and remove the transmission control
solenoid body by pulling down on the transmission control solenoid body and pushing down on the
transmission solenoid body connector from the other side of the case.
Installation
1. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the
O-ring seals with clean transmission fluid.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4556
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 transmission control solenoid body. Tighten the transmission control solenoid body
screws in sequence shown. ^
Tighten to 8 Nm (71 lb-inch).
3. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with
clean transmission fluid.
NOTE: Make sure that the transmission fluid pan filter seals are correctly seated on the
transmission fluid pan filter.
Lubricate the transmission fluid pan seals and install the transmission fluid pan filter. ^
Tighten to 10 Nm (89 lb-inch).
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
reused.
Install the transmission fluid pan and transmission fluid pan gasket and loosely install the
transmission fluid pan screws.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 4557
5. Tighten the transmission fluid pan screws in a crisscross sequence.
^ Tighten to 11 Nm (8 lb-ft).
6. CAUTION: Damage will occur to the transmission control solenoid body assembly if the screw is
tightened above the specification.
NOTE: Always install new O-ring seals on transmission control solenoid body harness connector.
NOTE: Clean the area around transmission control solenoid body harness connector to prevent
contamination of the transmission control solenoid body harness 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 control solenoid body harness connector
and connect the connector. ^
Tighten to 5 Nm (44 lb-inch).
7. Fill the transmission.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Application Chart
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4563
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4564
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4565
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4566
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4567
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4568
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4569
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4570
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4571
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4572
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4573
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4574
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 4575
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4576
Torque Converter Clutch Solenoid: Service and Repair
Solenoid Body Assembly
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4577
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid drain plug
and drain the transmission fluid.
3. NOTE: Clean the area around transmission control solenoid body harness connector to prevent
contamination of the transmission control solenoid
body harness connector.
Disconnect the transmission control solenoid body harness connector.
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
reused.
Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan
gasket.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4578
5. Remove the transmission fluid pan filter.
6. CAUTION: Do not damage the solenoid body connector pins.
Remove the transmission control solenoid body screws and remove the transmission control
solenoid body by pulling down on the transmission control solenoid body and pushing down on the
transmission solenoid body connector from the other side of the case.
Installation
1. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the
O-ring seals with clean transmission fluid.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4579
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 transmission control solenoid body. Tighten the transmission control solenoid body
screws in sequence shown. ^
Tighten to 8 Nm (71 lb-inch).
3. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with
clean transmission fluid.
NOTE: Make sure that the transmission fluid pan filter seals are correctly seated on the
transmission fluid pan filter.
Lubricate the transmission fluid pan seals and install the transmission fluid pan filter. ^
Tighten to 10 Nm (89 lb-inch).
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
reused.
Install the transmission fluid pan and transmission fluid pan gasket and loosely install the
transmission fluid pan screws.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 4580
5. Tighten the transmission fluid pan screws in a crisscross sequence.
^ Tighten to 11 Nm (8 lb-ft).
6. CAUTION: Damage will occur to the transmission control solenoid body assembly if the screw is
tightened above the specification.
NOTE: Always install new O-ring seals on transmission control solenoid body harness connector.
NOTE: Clean the area around transmission control solenoid body harness connector to prevent
contamination of the transmission control solenoid body harness 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 control solenoid body harness connector
and connect the connector. ^
Tighten to 5 Nm (44 lb-inch).
7. Fill the transmission.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component
Information > Specifications > Band Adjustment and Torque Chart - 5R55S
Band: Specifications Band Adjustment and Torque Chart - 5R55S
Band Adjustment and Torque Chart
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component
Information > Specifications > Band Adjustment and Torque Chart - 5R55S > Page 4585
Band: Specifications Band and Clutch Application Chart A - 5R55S
Band and Clutch Application Chart A
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component
Information > Specifications > Band Adjustment and Torque Chart - 5R55S > Page 4586
Band: Specifications Band and Clutch Application Chart B - 5R55S
Band and Clutch Application Chart B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 4595
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 (V8-4.6L (2008))
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 4596
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 (V8-4.6L (2008))
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 4597
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 (V8-4.6L (2008))
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 4598
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 4604
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 (V8-4.6L (2008))
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 4605
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 (V8-4.6L (2008))
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 4606
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 (V8-4.6L (2008))
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 4607
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 (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Diagrams > Diagram Information and Instructions > Page 4612
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Diagrams > Diagram Information and Instructions > Page 4613
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Diagrams > Diagram Information and Instructions > Page 4614
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Diagrams > Diagram Information and Instructions > Page 4615
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Diagrams > Diagram Information and Instructions > Page 4616
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Diagrams > Diagram Information and Instructions > Page 4617
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Diagrams > Diagram Information and Instructions > Page 4618
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Diagrams > Diagram Information and Instructions > Page 4619
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Diagrams > Diagram Information and Instructions > Page 4620
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Diagrams > Diagram Information and Instructions > Page 4621
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Diagrams > Diagram Information and Instructions > Page 4622
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Diagrams > Diagram Information and Instructions > Page 4623
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Diagrams > Diagram Information and Instructions > Page 4624
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Diagrams > Page 4625
Brake Switch - TCC: Description and Operation
BRAKE PEDAL POSITION (BPP) SWITCH
Typical BPP Switch
The BPP switch is sometimes referred to as the 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 antilock 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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 4634
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 (V8-4.6L (2008))
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 4635
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 (V8-4.6L (2008))
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 4636
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 (V8-4.6L (2008))
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 4637
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 4643
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 (V8-4.6L (2008))
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 4644
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 (V8-4.6L (2008))
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 4645
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 (V8-4.6L (2008))
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 4646
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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Specifications > Clutch Application Chart - 6R60
Clutch: Specifications Clutch Application Chart - 6R60
Clutch Application Chart
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Specifications > Clutch Application Chart - 6R60 > Page 4651
Clutch: Specifications Clutch Plate Quantity - 6R60
Clutch Plate Quantity
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 09-22-6 > Nov > 09 >
Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle
Control Module: Customer Interest Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle
TSB 09-22-6
11/16/09
4.6L ENGINE -CHECK ENGINE LIGHT ON - DTC P0196 - COLD WEATHER DRIVING
CONDITIONS- CALIBRATION UPDATE
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
ISSUE Some 2006-2008 Explorer, Mountaineer and Sport Trac vehicles and equipped with 4.6L
3-V engines may exhibit:
^ Diagnostic trouble code (DTC) P0196 - engine oil temperature (EOT) sensor range/performance
during ice/snow driving conditions.
^ Idle speed dropping below specification, hesitation or loss of RPM with no DTCs stored in the
Powertrain Control Module (PCM).
^ Cruise control surge at approximately 50-60 MPH (80-97 Km/h) in hilly regions Only applies to
vehicles operated in altitudes above 5000 feet (1.52
km).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
If normal Powertrain Controls/Emissions Diagnosis (PC/ED) diagnostics do not resolve the above
vehicle concerns, reprogram the PCM and Transmission Control Module (1CM) to the latest
calibration using IDS release 63.08 and higher. This new calibration is not included in the VCM
2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
VEHICLES EQUIPPED WITH A PCM AND TCM, REQUIRE A COORDINATED
REPROGRAMMING.
THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS
OUTLINED BY THE INTERGRATED DIAGNOSTIC SYSTEM (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 63.08 and higher. This new calibration
is not included in the VCM 2009.9 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:
(1) Choose all Tests and Calibrations.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 09-22-6 > Nov > 09 >
Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle > Page 4660
(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
DISCONNECTING 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 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. Brake gently to a complete
stop and hold foot on brake for at least 10 seconds.
g. Repeat Steps (e-f) a total of three (3) 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
092206A 2006-2008 Explorer, 1.0 Hr.
Mountaineer 2007-2008 Explorer Sport Trac: Check DTCs, Reprogram The PCM And TCM
Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor
Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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: > 09-22-6 > Nov
> 09 > Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle
Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0196/RPM
Loss/Slow Idle
TSB 09-22-6
11/16/09
4.6L ENGINE -CHECK ENGINE LIGHT ON - DTC P0196 - COLD WEATHER DRIVING
CONDITIONS- CALIBRATION UPDATE
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
ISSUE Some 2006-2008 Explorer, Mountaineer and Sport Trac vehicles and equipped with 4.6L
3-V engines may exhibit:
^ Diagnostic trouble code (DTC) P0196 - engine oil temperature (EOT) sensor range/performance
during ice/snow driving conditions.
^ Idle speed dropping below specification, hesitation or loss of RPM with no DTCs stored in the
Powertrain Control Module (PCM).
^ Cruise control surge at approximately 50-60 MPH (80-97 Km/h) in hilly regions Only applies to
vehicles operated in altitudes above 5000 feet (1.52
km).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
If normal Powertrain Controls/Emissions Diagnosis (PC/ED) diagnostics do not resolve the above
vehicle concerns, reprogram the PCM and Transmission Control Module (1CM) to the latest
calibration using IDS release 63.08 and higher. This new calibration is not included in the VCM
2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
VEHICLES EQUIPPED WITH A PCM AND TCM, REQUIRE A COORDINATED
REPROGRAMMING.
THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS
OUTLINED BY THE INTERGRATED DIAGNOSTIC SYSTEM (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 63.08 and higher. This new calibration
is not included in the VCM 2009.9 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:
(1) Choose all Tests and Calibrations.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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: > 09-22-6 > Nov
> 09 > Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle > Page 4666
(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
DISCONNECTING 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 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. Brake gently to a complete
stop and hold foot on brake for at least 10 seconds.
g. Repeat Steps (e-f) a total of three (3) 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
092206A 2006-2008 Explorer, 1.0 Hr.
Mountaineer 2007-2008 Explorer Sport Trac: Check DTCs, Reprogram The PCM And TCM
Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor
Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Page 4667
View 151-12
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Page 4668
C199
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Specifications > Capacity Specifications
Fluid - A/T: Capacity Specifications
Transmission Fluid 5R55 .....................................................................................................................
............................................................................... 12.4 Quarts ( 11.7 L ) 6R60 .................................
..............................................................................................................................................................
..... 12.2 Quarts ( 11.6 L )
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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Specifications > Capacity Specifications > Page 4673
Fluid - A/T: Fluid Type Specifications
Transmission Fluid Type
5R55S ..................................................................................................................................................
............................................................. MERCON V 6R60 ..................................................................
..............................................................................................................................................
MERCON SP
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission
Fluid - A/T: Service and Repair 5R55S - Automatic Transaxle/Transmission
Transmission Fluid Level Check
Transmission Fluid Level Check
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4676
Transmission 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 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. 7. Hold the larger transmission fluid drain plug with
a wrench and remove the small (center) transmission fluid level indicating plug.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4677
8. Install the special tool into the pan.
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 transmission fluid.
10. Hang the special tool under the vehicle. Position it upright and close to the transmission.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4678
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. Transmission fluid will immediately
start flowing out of the special tool into the transmission fluid pan.
13. Add 0.5L (1 pt) of transmission fluid into the transmission fluid pan. Stop the process by
releasing the air pressure and removing the air nozzle
from the end of the hose.
14. Inspect the transmission fluid level in the special tool. If the transmission fluid drains back into
the canister, the transmission is full. If no
transmission fluid drains back, more transmission 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 transmission fluid trapped in the system and direct it into the
container.
16. Allow the transmission fluid to drain. Make sure that the fluid temperature is between 27-49° C
(80-120° F). When the transmission fluid comes
out as a thin stream or drip, the transmission fluid is at the correct level.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4679
17. Reinstall the small (center) transmission fluid level indicating plug using a 3/16-inch Allen key.
^ Tighten to 10 Nm (89 lb-inch).
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.
Transmission Fluid Drain and Refill - Automated Equipment
Transmission Fluid Drain and Refill - Automated Equipment
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 or transmission
damage can occur.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4680
1. With the vehicle in PARK, position it on a hoist. 2. Use a suitable flush and fill machine to change
the fluid. 3. When connecting the flush and fill machine, connect the machine to the transmission
fluid cooler tube after the transmission fluid cooler on the
transmission fluid cooler return tube. This will help remove any foreign material trapped in the
transmission fluid coolers.
Refill
1. Use only clean transmission fluid. 2. Once the transmission 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
transmission fluid is needed, add transmission
fluid in increments of 0.24L (0.5 pt) until the correct level is achieved. For additional information,
refer to Transmission Fluid Level Check. See: Service and Repair/Procedures/Transmission Fluid
Level Check
Transmission Fluid Drain and Refill -Without Torque Converter Drain Plug
Transmission Fluid Drain and Refill -Without Torque Converter Drain Plug
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4681
Fluid Fill Reference
NOTE: Left side of case shown.
Fluid Fill Reference
Draining
1. With the vehicle in PARK, position it on a hoist. Set the vehicle as close to level as possible. 2.
Remove the transmission fluid drain plug (large plug) and allow the fluid to drain.
Refill
1. Install the transmission fluid drain plug.
^ Tighten to 26 Nm (19 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4682
2. Hold the larger transmission fluid drain plug with a wrench and remove the small (center)
transmission fluid level indicating plug.
3. Install the special tool into the transmission fluid 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 transmission fluid.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4683
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.
7. Apply a maximum of 206.85 kPa (30 psi) to the open end of the vacuum/pressure hose from the
special tool. Transmission fluid will immediately
start flowing out of the special tool into the transmission fluid pan.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4684
8. Add 1.89L or 2.83L (2 qt or 3 qt) of transmission fluid into the transmission 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 transmission fluid level in the special tool. If the fluid drains back into the canister,
the transmission is full. If no transmission fluid
drains back, more transmission 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 transmission fluid to drain. When the transmission fluid comes out as a thin stream or
drip, the transmission fluid is at the correct level.
13. Reinstall the small (center) transmission fluid level indicating plug.
^ Tighten to 10 Nm (89 lb-inch).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4685
Transmission Fluid Cooler Backflushing and Cleaning
Transmission Fluid Cooler Backflushing and Cleaning
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. Failure to follow these instructions
may result in transmission failure.
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. ^
Connect the cleaner tank pressure line to the steel transmission cooler return tube (longest tube).
^ Connect a tank return hose to the steel transmission cooler pressure tube (shorter tube). 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 tube.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4686
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 tube.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4687
Fluid - A/T: Service and Repair 6R60 - Automatic Transaxle/Transmission
Transmission Fluid Level Check
Transmission Fluid Level Check
CAUTION: The vehicle should not be driven if the transmission fluid level is low as internal failure
could result.
CAUTION: The transmission fluid fill plug is located near the exhaust system. The exhaust will be
extremely hot during this procedure.
NOTE: If the vehicle has been operated for an extended period at high highway speeds, in city
traffic, during hot weather or while pulling a trailer, the transmission fluid must cool down to obtain
an accurate reading.
NOTE: If the transmission starts to slip, shifts slowly or shows signs of transmission fluid leaking,
the transmission fluid level should be checked.
NOTE: Do not overfill the transmission. The transmission fluid level must be at the upper level of
the crosshatch mark.
NOTE: If the installation of a new transmission fluid cooler, cooler tubes have been carried out the
vehicle must be driven to get the transmission fluid to a temperature of 88° C (190° F) in order to
purge the air from the transmission fluid cooling system.
1. With the engine running, place the transmission selector lever in each gear position and hold
approximately 5 seconds. Place the transmission
selector lever in PARK.
2. With the engine idling (600-750 rpm) in PARK, position it on a hoist. 3. Remove the transmission
fluid fill plug transmission fluid level indicator assembly, located on the passenger side front portion
of the transmission
case.
4. Separate the transmission fluid level indicator from the transmission fluid fill plug.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4688
5. Wipe the transmission fluid level indicator clean. Reinstall the transmission fluid level indicator
only back into the transmission fluid fill plug hole
to check the transmission fluid level.
6. Using the scan tool, verify that the transmission fluid temperature is between 80° C-85° C (175°
F-185° F). Do not overfill the transmission. The
transmission fluid level must be at the upper level of the crosshatch mark.
7. NOTE: If the transmission fluid is not at the correct level, follow the steps for Adding Additional
Transmission Fluid or Removing Transmission
Fluid.
Install the transmission fluid fill plug. ^
Tighten to 35 Nm (26 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4689
Transmission Fluid Drain and Refill
Transmission Fluid Drain and Refill
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4690
Drain
1. With the vehicle in NEUTRAL, position it on a hoist.
2. NOTE: Some transmission fluid leakage may occur when removing the transmission fluid fill
plug.
Remove the transmission fluid fill plug transmission fluid level indicator assembly located on the
passenger side front portion of the transmission case. Removal of the transmission fluid fill plug will
relieve any vacuum that might have built up in the transmission. This will aid in allowing the
transmission fluid pan to be easily removed when the bolts are removed.
3. Remove the transmission fluid pan and allow the transmission fluid to drain.
4. NOTE: The transmission fluid pan gasket can be reused if not damaged.
Install a new transmission fluid pan gasket, if required.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4691
5. Install the transmission fluid pan.
^ Tighten to 14 Nm (10 lb-ft).
Transmission Fluid Refill
CAUTION: This procedure contains the air purge steps required to purge air from the transmission
fluid cooling system. This procedure is NOT intended for use with the Transmission Fluid Level
Check.
CAUTION: The vehicle should not be driven if the transmission fluid level is low as internal failure
could result.
CAUTION: The transmission fluid fill plug is located near the exhaust system. The exhaust will be
extremely hot during this procedure.
CAUTION: The use of any other transmission fluid than specified, can result in the transmission
failing to operate in a normal manner or transmission failure.
NOTE: If the transmission starts to slip, shifts slowly or shows signs of transmission fluid leaking,
the transmission fluid level should be checked.
NOTE: Here is an overview of the Transmission Fluid Drain and Refill procedure.
^ Adding 3.3L (3.5 qt) of clean transmission fluid to the transmission is an initial fill enabling you to
start the engine.
^ The cold transmission fluid level range shown in the procedure allows the vehicle to be driven.
^ The vehicle should be driven to allow the transmission fluid temperature to reach 85° C-88° C
(185° F-190° F) in order to purge the air from the transmission fluid cooling system.
^ Fill the transmission fluid to the full range on the transmission fluid level indicator at the normal
operating range 80° C-85° C (175° F-185° F).
1. NOTE: The transmission will need 3.3L (3.5 qt) of clean transmission fluid added to the
transmission as an initial fill if:
^ the transmission has been overhauled.
^ a new mechatronic assembly has been installed.
^ the transmission fluid pan or transmission fluid filter have been removed.
Using the special tool, add 3.3L (3.5 qt) of clean transmission fluid to the transmission through the
transmission fluid fill hole.
2. Check the transmission fluid level cold.
1 The vehicle is safe to drive if the transmission fluid is in the cold level range 32° C-43° C (90°
F-110° F).
^ With the engine running, use the scan tool to monitor transmission fluid temperature and engine
speed. Place the transmission selector lever in each gear position and hold approximately 5
seconds. Place the transmission selector lever in PARK, with the engine at idle (600-750 rpm).
3. Separate the transmission fluid level indicator from the transmission fluid fill plug.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4692
4. Wipe the transmission fluid level indicator clean. Reinstall the transmission fluid level indicator
only back into the transmission fluid fill plug hole
to check the transmission fluid level. Repeat this until a consistent reading is established.
5. Add clean transmission fluid to the cold level location as shown in the illustration.
1 Transmission fluid cold level.
6. Install the transmission fluid fill plug.
^ Tighten to 35 Nm (26 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4693
7. While driving the vehicle, use the scan tool to verify that the transmission fluid temperature has
reached a temperature of 88° C (190° F). This will
circulate the transmission fluid through the torque converter and the transmission fluid cooling
system, eliminating any trapped air in the cooling system. ^
With the engine idling (600-750 rpm) in PARK, verify that the transmission fluid temperature is
between 80° C-85° C (175° F-185° F).
8. Remove the transmission fluid fill plug transmission fluid level indicator assembly located on the
passenger side front portion of the transmission
case.
9. Separate the transmission fluid level indicator from the transmission fluid fill plug.
10. Wipe the transmission fluid level indicator clean. Reinstall the transmission fluid level indicator
only back into the transmission fluid fill plug hole
to check the transmission fluid level. Repeat this until a consistent reading is established.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4694
11. Using the scan tool verify that the transmission fluid temperature is between 80° C-85° C (175°
F-185° F). The transmission fluid level must be at
the upper level of the crosshatch mark.
12. NOTE: If the transmission fluid is not at the correct level, follow the steps for Adding Additional
Transmission Fluid or Removing Transmission
Fluid in this procedure.
Install the transmission fluid fill plug. ^
Tighten to 35 Nm (26 lb-ft).
Adding Additional Transmission Fluid
NOTE: To get an accurate transmission fluid level reading the engine should be idling (600-750
rpm) in PARK.
1. Install the special tool into the transmission fluid fill hole.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4695
2. Fill the special tool with approximately 0.47L (1 pt) of clean transmission fluid.
3. Hang the special tool under the vehicle, upright and close to the transmission.
4. Connect the special tools.
^ Connect the open end of the hose from the special tool onto the special tool from the
transmission case.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4696
5. Apply a maximum of 206.85 kPa (30 psi) to the open end of the vacuum/pressure hose from the
special tool. Transmission fluid will immediately
start flowing out of the special tool into the transmission.
6. NOTE: Do not overfill the transmission. The transmission fluid level must be at the upper level of
the crosshatch mark.
Reinstall the transmission fluid level indicator only back into the transmission fluid fill plug hole to
check the transmission fluid level. Repeat this until a consistent reading is established.
7. Using the scan tool verify that the transmission fluid temperature is between 80° C-85° C (175°
F-185° F). The transmission fluid level must be at
the upper level of the crosshatch mark.
8. NOTE: If the transmission fluid is over full, follow the steps for Removing Transmission Fluid in
this procedure.
Install the transmission fluid fill plug. ^
Tighten to 35 Nm (26 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4697
Removing Transmission Fluid
NOTE: To get an accurate transmission fluid level reading the engine should be idling (600-750
rpm) in PARK.
1. If the transmission is overfilled, transmission fluid must be removed to the correct level. Use the
special tools to extract any excessive transmission
fluid.
2. Using the scan tool, verify that the transmission fluid temperature is between 80° C-85° C (175°
F-185° F). The transmission fluid level must be at
the upper level of the crosshatch mark. Reinstall the transmission fluid level indicator only back into
the transmission fluid fill plug hole to check the transmission fluid level. Repeat this until a
consistent reading is established.
3. Install the transmission fluid fill plug.
^ Tighten to 35 Nm (26 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4698
Transmission Fluid Cooler Backflushing and Cleaning
Transmission Fluid Cooler Backflushing and Cleaning
CAUTION: When internal damage occurs in the transmission, metal particles and clutch plate
material can travel into the torque converter and the transmission fluid cooler. These contaminates
are a major cause of recurring transmission concerns. To prevent further concerns, remove these
contaminates from the transmission fluid cooler tubes and install a new transmission fluid cooler
before placing the transmission in use.
CAUTION: Do not attempt to install an in-line transmission fluid filter on this vehicle, damage to the
transmission fluid cooling system or transmission could occur.
1. Install a new transmission fluid cooler if any transmission fluid leaks are indicated or a major
metallic failure is indicated. 2. Using a suitable torque converter/fluid cooler cleaner, flush the
transmission fluid cooler and tubes.
3. NOTE: Rubber hoses must be attached to the ends of the transmission fluid cooler tubes, to aid
in connecting them to the cleaner.
Connect the cleaner pressure and return lines appropriately in the following sequence. 1
Connect the pressure line to the transmission fluid cooler inlet tube.
2 Connect the return line to the transmission fluid cooler outlet tube.
3 Place the outlet end of the return line in the transmission fluid tank reservoir.
4. NOTE: Cycling the fluid pump ON and OFF will help dislodge contaminants in the cooler system.
Switch the fluid pump ON. Allow the transmission fluid to circulate a minimum of 5 minutes.
5. Switch the fluid pump OFF. 6. Disconnect the cleaner pressure line at the transmission fluid
cooler tube. 7. Using compressed air, blow through the transmission fluid cooler inlet tube until all
transmission fluid is removed. 8. Remove the rubber hoses from the transmission fluid cooler
tubes.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission
Fluid Filter - A/T: Service and Repair 5R55S - Automatic Transaxle/Transmission
Fluid Pan, Gasket and Filter
Fluid Pan, Gasket and Filter
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Place a drain pan under the transmission
fluid pan.
3. Remove the transmission fluid drain plug and drain the transmission fluid.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4703
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid gasket should be
reused.
Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid gasket.
5. Remove and discard the transmission fluid pan filter.
6. Clean and inspect the transmission fluid pan and magnet.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4704
Installation
1. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with
clean transmission fluid.
NOTE: Make sure that the transmission fluid filter seals are correctly seated on the transmission
fluid filter.
Lubricate the transmission fluid filter seals and install the transmission fluid pan filter. ^
Tighten to 10 Nm (89 lb-inch).
2. Install the transmission 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 transmission fluid pan gasket should be
reused.
Install the transmission fluid pan gasket on the transmission fluid pan.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4705
4. Install the transmission fluid pan and transmission fluid pan gasket and loosely install the
transmission fluid pan screws.
5. Tighten the transmission fluid pan screws in a crisscross sequence.
^ Tighten to 11 Nm (8 lb-ft).
6. Install the transmission fluid drain plug.
^ Tighten to 26 Nm (19 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4706
7. Partially fill the transmission.
Transmission Filter - In Line
Transmission Filter - In Line
NOTE: Use the following guidelines for installing the transmission fluid in-line filter:
^ If the transmission was overhauled and the vehicle was equipped with an in-line transmission
fluid filter, install a new in-line transmission fluid filter.
^ If the transmission was overhauled and the vehicle was not equipped with an in-line transmission
fluid filter, install a new in-line transmission fluid filter kit.
^ If the transmission is being installed for a non-internal repair, do not install an in-line transmission
fluid filter or in-line transmission fluid filter kit.
^ If installing a Ford-authorized remanufactured transmission, install a new in-line transmission fluid
filter.
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the secondary latch from the
transmission fluid cooler connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4707
3. Using the special tool, disconnect the transmission fluid cooler connector.
4. Remove the section of the transmission fluid cooler tube at the second flare.
^ Clean and deburr the cut end of the transmission fluid cooler tube.
5. NOTE: Be sure the transmission fluid 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 transmission 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 transmission fluid cooler hose as illustrated.
7. CAUTION: The transmission fluid cooler filter has a bypass valve in it. The red arrow on the
transmission fluid filter indicates the
direction of transmission fluid flow through the filter. The transmission fluid filter must be installed in
the transmission fluid cooler return line with the red arrow on the transmission fluid filter pointing
away from the transmission fluid cooler and toward the transmission (the transmission fluid return
line has transmission fluid coming out of the transmission fluid cooler going to the transmission). If
the transmission fluid filter is not installed correctly, it will cause internal transmission damage.
CAUTION: Do not install any transmission fluid cooler hoses or transmission fluid cooler tubes with
a bend entering the transmission fluid filter greater than 60 degrees. Doing so can block
transmission fluid flow and cause internal transmission damage.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4708
Install the one end of the transmission fluid filter into the transmission fluid cooler hose with a
clamp. ^
Tighten the transmission fluid cooler hose clamp.
8. Using a suitable length of hose, install the other end of the transmission fluid filter into the tubing
ferrule hose assembly with 2 clamps.
^ Tighten the hose clamps.
9. Clean a section of the transmission fluid pan, then install the sticker.
10. Fill the transmission with clean transmission fluid.
^ Verify for correct operation.
^ Check the filter for leaks.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4709
Fluid Filter - A/T: Service and Repair 6R60 - Automatic Transaxle/Transmission
Fluid Pan, Gasket and Filter
Removal
CAUTION: The use of any other transmission fluid than specified, can result in the transmission
failing to operate in a normal manner or transmission failure.
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid fill plug
transmission fluid level indicator assembly located on the passenger side front portion of the
transmission
case. Removal of the transmission fluid fill plug will relieve any vacuum that might have built up in
the transmission. This will allow the transmission fluid pan to be easily removed when the bolts are
removed.
3. Remove the transmission fluid pan and allow the transmission fluid to drain.
4. Remove the transmission fluid pan gasket.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4710
5. Remove and discard the transmission fluid filter.
6. Clean and inspect the transmission fluid pan and magnet.
Installation
NOTE: If the transmission is being repaired for a contamination-related failure, install a new
transmission fluid filter and seal assembly. The transmission fluid filter may be reused if no
excessive contamination is indicated.
1. Inspect the transmission case for the transmission fluid filter seal. If the transmission fluid filter
seal is in the case, carefully remove the
transmission fluid filter seal without scratching the case.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4711
2. Make sure that the transmission fluid filter seal is on the transmission fluid filter and lubricate the
transmission fluid filter seal with clean
transmission fluid.
3. Install a new transmission fluid filter.
4. Position the magnet in the transmission fluid pan.
5. NOTE: The transmission fluid pan gasket can be reused if not damaged.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4712
Install a new transmission fluid pan gasket if required.
6. Install the transmission fluid pan and tighten the bolts in a crisscross pattern.
^ Tighten to 14 Nm (10 lb-ft).
7. Using the transmission fluid refill procedure, fill the transmission with clean transmission fluid.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Technical Service Bulletins > Recalls for Fluid Line/Hose: > NHTSA07V453000 > Sep > 07 >
Recall 07V453000: A/T Cooler Line Bolt Torque
Fluid Line/Hose: Recalls Recall 07V453000: A/T Cooler Line Bolt Torque
MAKE/MODELS: MODEL/BUILD YEARS: Ford/Explorer 2008 Ford/Explorer Sport Trac 2008
Mercury/Mountaineer 2008 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID
NUMBER: 07V453000 MFR'S REPORT DATE: August 28, 2007
COMPONENT: Power Train: Automatic Transmission: Cooling Unit and Lines
POTENTIAL NUMBER OF UNITS AFFECTED: 1497
SUMMARY: On certain sport utility vehicles equipped with the 4.6l engine and 6R transmission, the
bolt securing the transmission oil cooler line fittings at the transmission may not have been
sufficiently torqued during vehicle assembly. AS A RESULT, THE BOLT MAY LOOSEN AND THE
TRANSMISSION OIL COOLER LINES MAY DISENGAGE FROM THE TRANSMISSION,
CAUSING A TRANSMISSION FLUID LEAK.
CONSEQUENCE: If leaking transmission fluid contacts the catalytic converter, it may pose a risk of
fire.
REMEDY: Dealers will inspect and have the transmission cooler line attachment bolt tightened free
of charge. The recall began on August 30, 2007. Owners may contact Ford at 1-800-392-3673.
NOTES: Ford recall No. 07S56. Customers may also contact The National Highway Traffic Safety
Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to
http://www.safercar.gov.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Technical Service Bulletins > Recalls for Fluid Line/Hose: > 07S56 > Aug > 07 > Recall - A/T
Cooler Line Leakage/Fire Potential
Technical Service Bulletin # 07S56 Date: 070822
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Technical Service Bulletins > Recalls for Fluid Line/Hose: > 07S56 > Aug > 07 > Recall - A/T
Cooler Line Leakage/Fire Potential > Page 4725
Attachment I - Administrative Information
OASIS ACTIVATED?
Yes. OASIS will be activated by August 22, 2007.
FSA VIN LIST ACTIVATED?
Yes. Available through the website by August 22, 2007. Owner names and addresses will be
available by September 7, 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 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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Technical Service Bulletins > Recalls for Fluid Line/Hose: > 07S56 > Aug > 07 > Recall - A/T
Cooler Line Leakage/Fire Potential > Page 4726
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.
OWNER REFUNDS
Refunds are not authorized for this program.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
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 prior 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
LABOR ALLOWANCES
PARTS REQUIREMENTS / ORDERING INFORMATION
Parts are not required for this repair.
Attachment III - Technical Information
1. Lift vehicle and locate the transmission fluid cooler line attachment bolt on the left side of the
transmission. (See illustration.)
NOTE:
If cooler lines are leaking transmission fluid at the transmission attachment point, call Special
Service Support Center.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Technical Service Bulletins > Recalls for Fluid Line/Hose: > 07S56 > Aug > 07 > Recall - A/T
Cooler Line Leakage/Fire Potential > Page 4727
2. Tighten Transmission Fluid Cooler Line Attachment bolt to 25 Nm (18 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Technical Service Bulletins > Recalls for Fluid Line/Hose: > 07S56 > Aug > 07 > Recall - A/T
Cooler Line Leakage/Fire Potential > Page 4728
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Technical Service Bulletins > Recalls for Fluid Line/Hose: > 07S56 > Aug > 07 > Recall - A/T
Cooler Line Leakage/Fire Potential > Page 4729
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Line/Hose: >
NHTSA07V453000 > Sep > 07 > Recall 07V453000: A/T Cooler Line Bolt Torque
Fluid Line/Hose: All Technical Service Bulletins Recall 07V453000: A/T Cooler Line Bolt Torque
MAKE/MODELS: MODEL/BUILD YEARS: Ford/Explorer 2008 Ford/Explorer Sport Trac 2008
Mercury/Mountaineer 2008 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID
NUMBER: 07V453000 MFR'S REPORT DATE: August 28, 2007
COMPONENT: Power Train: Automatic Transmission: Cooling Unit and Lines
POTENTIAL NUMBER OF UNITS AFFECTED: 1497
SUMMARY: On certain sport utility vehicles equipped with the 4.6l engine and 6R transmission, the
bolt securing the transmission oil cooler line fittings at the transmission may not have been
sufficiently torqued during vehicle assembly. AS A RESULT, THE BOLT MAY LOOSEN AND THE
TRANSMISSION OIL COOLER LINES MAY DISENGAGE FROM THE TRANSMISSION,
CAUSING A TRANSMISSION FLUID LEAK.
CONSEQUENCE: If leaking transmission fluid contacts the catalytic converter, it may pose a risk of
fire.
REMEDY: Dealers will inspect and have the transmission cooler line attachment bolt tightened free
of charge. The recall began on August 30, 2007. Owners may contact Ford at 1-800-392-3673.
NOTES: Ford recall No. 07S56. Customers may also contact The National Highway Traffic Safety
Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to
http://www.safercar.gov.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Line/Hose: > 07S56 > Aug >
07 > Recall - A/T Cooler Line Leakage/Fire Potential
Technical Service Bulletin # 07S56 Date: 070822
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Line/Hose: > 07S56 > Aug >
07 > Recall - A/T Cooler Line Leakage/Fire Potential > Page 4739
Attachment I - Administrative Information
OASIS ACTIVATED?
Yes. OASIS will be activated by August 22, 2007.
FSA VIN LIST ACTIVATED?
Yes. Available through the website by August 22, 2007. Owner names and addresses will be
available by September 7, 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 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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Line/Hose: > 07S56 > Aug >
07 > Recall - A/T Cooler Line Leakage/Fire Potential > Page 4740
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.
OWNER REFUNDS
Refunds are not authorized for this program.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
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 prior 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
LABOR ALLOWANCES
PARTS REQUIREMENTS / ORDERING INFORMATION
Parts are not required for this repair.
Attachment III - Technical Information
1. Lift vehicle and locate the transmission fluid cooler line attachment bolt on the left side of the
transmission. (See illustration.)
NOTE:
If cooler lines are leaking transmission fluid at the transmission attachment point, call Special
Service Support Center.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Line/Hose: > 07S56 > Aug >
07 > Recall - A/T Cooler Line Leakage/Fire Potential > Page 4741
2. Tighten Transmission Fluid Cooler Line Attachment bolt to 25 Nm (18 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Line/Hose: > 07S56 > Aug >
07 > Recall - A/T Cooler Line Leakage/Fire Potential > Page 4742
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Line/Hose: > 07S56 > Aug >
07 > Recall - A/T Cooler Line Leakage/Fire Potential > Page 4743
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S
Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Tubes - 5R55S
Transmission Fluid Cooler Tubes - 5R55S
Removal
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4746
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Using a backup wrench to hold the case
fitting securely, disconnect the transmission fluid cooler tubes.
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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4747
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4748
9. Remove the transmission cooler tubes from the vehicle.
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 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4749
4. CAUTION: To prevent cross threading, all transmission fluid cooler tube nuts must be hand
started before being tightened to
specification.
Using a backup wrench to hold the case fittings securely, install the transmission fluid cooler tubes.
^
Tighten to 40 Nm (30 lb-ft).
5. Install the transmission fluid cooler tube bracket nut.
^ Tighten to 25 Nm (18 lb-ft).
6. Connect the transmission fluid cooler tube to the transmission fluid cooler hose.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4750
7. Install the secondary latch.
8. Connect the transmission fluid cooler tube to the radiator.
9. Install the secondary latch.
10. Fill transmission fluid to the correct level using clean transmission fluid and inspect for leak.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4751
Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Tubes - 6R60
Transmission Fluid Cooler Tubes - 6R60
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4752
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the secondary latch from the
transmission fluid cooler tube.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4753
3. Using the special tool, disconnect the quick connect coupler and remove the transmission fluid
cooler tube from the radiator.
4. Remove the secondary latch from the transmission fluid cooler tube.
5. Using the special tool, disconnect the quick connect coupler and separate the transmission fluid
cooler tube from the transmission fluid cooler
hose.
6. Remove the transmission fluid cooler tube bracket nut.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4754
7. If equipped, index-mark the front driveshaft to maintain driveshaft balance.
8. If equipped, remove the 4 U-joint strap bolts and remove the U-joint straps.
^ Discard the bolts.
9. Disconnect the engine oil low level sensor electrical connector and harness clips.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4755
10. NOTE: The transmission fluid cooler tube O-rings may remain in the transmission case.
Carefully remove them from the case.
Remove the bolt and disconnect the transmission fluid cooler tubes from the transmission.
11. Remove and discard the 4 O-rings from the transmission fluid cooler tube ends.
12. Remove the transmission fluid cooler tubes from the vehicle.
Installation
1. Position the transmission fluid cooler tubes in the vehicle.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4756
2. Install 4 new O-rings on the transmission fluid cooler tube ends.
3. NOTE: Inspect the transmission case to make sure that the old O-rings are not stuck in the
transmission case.
Position the transmission fluid cooler tubes into the transmission, then install the bolt for the
transmission cooler tube retainer. ^
Tighten to 25 Nm (18 lb-ft).
4. Install the transmission fluid cooler tube bracket and install the transmission fluid cooler tube
bracket nut.
^ Tighten to 12 Nm (9 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4757
5. NOTE: Install new U-joint strap bolts. If new U-joint strap bolts are not available, coat the threads
of the original U-joint strap bolts with
Threadlock(R) and sealer.
If removed, install the U-joint straps and 4 new U-joint strap bolts. ^
Tighten to 19 Nm (14 lb-ft).
6. Connect the engine oil low level sensor electrical connector and harness clips.
7. Connect the transmission fluid cooler tube to the radiator.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4758
8. Install the secondary latch to the transmission fluid cooler tube at the radiator.
9. Connect the transmission fluid cooler tube to the transmission fluid cooler hose.
10. Install the secondary latch to the transmission fluid cooler tube at the cooler hose.
11. Fill the transmission fluid to the correct level, using clean transmission fluid, and inspect for
leaks.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4759
Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Hoses
Transmission Fluid Cooler Hoses
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4760
Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
Mountaineer
2. Remove the grille fasteners and the grille.
Explorer
3. Remove the bumper cover.
All vehicles
4. Remove the inner grille air deflector.
5. Push the lower air deflector down past the transmission fluid cooler.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4761
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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4762
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 hose 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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4763
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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4764
6. NOTE: Clean the transmission fluid 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes - 5R55S > Page 4765
Mountaineer
9. Install the grille and the fasteners.
Explorer
10. Install the bumper cover.
All vehicles
11. Fill the transmission fluid to the correct level using clean transmission fluid and inspect for
leaks.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Specifications > 5R55S - Automatic Transaxle/Transmission
Fluid Pan: Specifications 5R55S - Automatic Transaxle/Transmission
Transmission Fluid Pan Screws - 5R55S - Automatic Transaxle/Transmission
............................................. 11 Nm (8 lb-ft). in a crisscross sequence
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Specifications > 5R55S - Automatic Transaxle/Transmission > Page 4770
Fluid Pan: Specifications 6R60 - Automatic Transaxle/Transmission
Transmission Fluid Pan Screws - 6R60 - Automatic Transaxle/Transmission
................................................. 14 Nm (10 lb-ft). in a crisscross pattern
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission
Fluid Pan: Service and Repair 5R55S - Automatic Transaxle/Transmission
Fluid Pan, Gasket and Filter
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Place a drain pan under the transmission
fluid pan.
3. Remove the transmission fluid drain plug and drain the transmission fluid.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4773
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid gasket should be
reused.
Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid gasket.
5. Remove and discard the transmission fluid pan filter.
6. Clean and inspect the transmission fluid pan and magnet.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4774
Installation
1. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with
clean transmission fluid.
NOTE: Make sure that the transmission fluid filter seals are correctly seated on the transmission
fluid filter.
Lubricate the transmission fluid filter seals and install the transmission fluid pan filter. ^
Tighten to 10 Nm (89 lb-inch).
2. Install the transmission 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 transmission fluid pan gasket should be
reused.
Install the transmission fluid pan gasket on the transmission fluid pan.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4775
4. Install the transmission fluid pan and transmission fluid pan gasket and loosely install the
transmission fluid pan screws.
5. Tighten the transmission fluid pan screws in a crisscross sequence.
^ Tighten to 11 Nm (8 lb-ft).
6. Install the transmission fluid drain plug.
^ Tighten to 26 Nm (19 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4776
7. Partially fill the transmission.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4777
Fluid Pan: Service and Repair 6R60 - Automatic Transaxle/Transmission
Fluid Pan, Gasket and Filter
Removal
CAUTION: The use of any other transmission fluid than specified, can result in the transmission
failing to operate in a normal manner or transmission failure.
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid fill plug
transmission fluid level indicator assembly located on the passenger side front portion of the
transmission
case. Removal of the transmission fluid fill plug will relieve any vacuum that might have built up in
the transmission. This will allow the transmission fluid pan to be easily removed when the bolts are
removed.
3. Remove the transmission fluid pan and allow the transmission fluid to drain.
4. Remove the transmission fluid pan gasket.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4778
5. Remove and discard the transmission fluid filter.
6. Clean and inspect the transmission fluid pan and magnet.
Installation
NOTE: If the transmission is being repaired for a contamination-related failure, install a new
transmission fluid filter and seal assembly. The transmission fluid filter may be reused if no
excessive contamination is indicated.
1. Inspect the transmission case for the transmission fluid filter seal. If the transmission fluid filter
seal is in the case, carefully remove the
transmission fluid filter seal without scratching the case.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4779
2. Make sure that the transmission fluid filter seal is on the transmission fluid filter and lubricate the
transmission fluid filter seal with clean
transmission fluid.
3. Install a new transmission fluid filter.
4. Position the magnet in the transmission fluid pan.
5. NOTE: The transmission fluid pan gasket can be reused if not damaged.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4780
Install a new transmission fluid pan gasket if required.
6. Install the transmission fluid pan and tighten the bolts in a crisscross pattern.
^ Tighten to 14 Nm (10 lb-ft).
7. Using the transmission fluid refill procedure, fill the transmission with clean transmission fluid.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4789
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4790
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4791
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4792
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4793
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4794
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4795
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4796
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4797
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4798
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4799
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4800
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4801
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Specifications > 5R55S - Automatic Transaxle/Transmission
Pressure Regulating Solenoid: Specifications 5R55S - Automatic Transaxle/Transmission
Solenoid Operation Chart
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Specifications > 5R55S - Automatic Transaxle/Transmission > Page 4806
Pressure Regulating Solenoid: Specifications 6R60 - Automatic Transaxle/Transmission
Solenoid Application Chart
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4809
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4810
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4811
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4812
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4813
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4814
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4815
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4816
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4817
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4818
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4819
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4820
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4821
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Page 4822
Pressure Regulating Solenoid: Testing and Inspection
Pinpoint Tests - OSC Equipped Vehicle
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 the following shift solenoid operation information when carrying out Pinpoint Test A.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Page 4823
Solenoid Operation Chart (Part 1)
Solenoid Operation Chart (Part 2)
Shift Solenoid Failure Mode Chart
Failed ON or OFF due to PCM and/or vehicle wiring concerns, solenoid electrically, mechanically
or hydraulically stuck ON or OFF.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Page 4824
SSA, SSB
SSC, SSD
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Page 4825
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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Page 4826
Pressure Regulating Solenoid: Service and Repair
Solenoid Body Assembly
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Page 4827
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid drain plug
and drain the transmission fluid.
3. NOTE: Clean the area around transmission control solenoid body harness connector to prevent
contamination of the transmission control solenoid
body harness connector.
Disconnect the transmission control solenoid body harness connector.
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
reused.
Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan
gasket.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Page 4828
5. Remove the transmission fluid pan filter.
6. CAUTION: Do not damage the solenoid body connector pins.
Remove the transmission control solenoid body screws and remove the transmission control
solenoid body by pulling down on the transmission control solenoid body and pushing down on the
transmission solenoid body connector from the other side of the case.
Installation
1. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the
O-ring seals with clean transmission fluid.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Page 4829
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 transmission control solenoid body. Tighten the transmission control solenoid body
screws in sequence shown. ^
Tighten to 8 Nm (71 lb-inch).
3. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with
clean transmission fluid.
NOTE: Make sure that the transmission fluid pan filter seals are correctly seated on the
transmission fluid pan filter.
Lubricate the transmission fluid pan seals and install the transmission fluid pan filter. ^
Tighten to 10 Nm (89 lb-inch).
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
reused.
Install the transmission fluid pan and transmission fluid pan gasket and loosely install the
transmission fluid pan screws.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Page 4830
5. Tighten the transmission fluid pan screws in a crisscross sequence.
^ Tighten to 11 Nm (8 lb-ft).
6. CAUTION: Damage will occur to the transmission control solenoid body assembly if the screw is
tightened above the specification.
NOTE: Always install new O-ring seals on transmission control solenoid body harness connector.
NOTE: Clean the area around transmission control solenoid body harness connector to prevent
contamination of the transmission control solenoid body harness 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 control solenoid body harness connector
and connect the connector. ^
Tighten to 5 Nm (44 lb-inch).
7. Fill the transmission.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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: >
09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle
Control Module: Customer Interest Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle
TSB 09-22-6
11/16/09
4.6L ENGINE -CHECK ENGINE LIGHT ON - DTC P0196 - COLD WEATHER DRIVING
CONDITIONS- CALIBRATION UPDATE
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
ISSUE Some 2006-2008 Explorer, Mountaineer and Sport Trac vehicles and equipped with 4.6L
3-V engines may exhibit:
^ Diagnostic trouble code (DTC) P0196 - engine oil temperature (EOT) sensor range/performance
during ice/snow driving conditions.
^ Idle speed dropping below specification, hesitation or loss of RPM with no DTCs stored in the
Powertrain Control Module (PCM).
^ Cruise control surge at approximately 50-60 MPH (80-97 Km/h) in hilly regions Only applies to
vehicles operated in altitudes above 5000 feet (1.52
km).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
If normal Powertrain Controls/Emissions Diagnosis (PC/ED) diagnostics do not resolve the above
vehicle concerns, reprogram the PCM and Transmission Control Module (1CM) to the latest
calibration using IDS release 63.08 and higher. This new calibration is not included in the VCM
2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
VEHICLES EQUIPPED WITH A PCM AND TCM, REQUIRE A COORDINATED
REPROGRAMMING.
THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS
OUTLINED BY THE INTERGRATED DIAGNOSTIC SYSTEM (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 63.08 and higher. This new calibration
is not included in the VCM 2009.9 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:
(1) Choose all Tests and Calibrations.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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: >
09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle > Page 4840
(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
DISCONNECTING 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 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. Brake gently to a complete
stop and hold foot on brake for at least 10 seconds.
g. Repeat Steps (e-f) a total of three (3) 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
092206A 2006-2008 Explorer, 1.0 Hr.
Mountaineer 2007-2008 Explorer Sport Trac: Check DTCs, Reprogram The PCM And TCM
Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor
Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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: > 09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle
Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0196/RPM
Loss/Slow Idle
TSB 09-22-6
11/16/09
4.6L ENGINE -CHECK ENGINE LIGHT ON - DTC P0196 - COLD WEATHER DRIVING
CONDITIONS- CALIBRATION UPDATE
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
ISSUE Some 2006-2008 Explorer, Mountaineer and Sport Trac vehicles and equipped with 4.6L
3-V engines may exhibit:
^ Diagnostic trouble code (DTC) P0196 - engine oil temperature (EOT) sensor range/performance
during ice/snow driving conditions.
^ Idle speed dropping below specification, hesitation or loss of RPM with no DTCs stored in the
Powertrain Control Module (PCM).
^ Cruise control surge at approximately 50-60 MPH (80-97 Km/h) in hilly regions Only applies to
vehicles operated in altitudes above 5000 feet (1.52
km).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
If normal Powertrain Controls/Emissions Diagnosis (PC/ED) diagnostics do not resolve the above
vehicle concerns, reprogram the PCM and Transmission Control Module (1CM) to the latest
calibration using IDS release 63.08 and higher. This new calibration is not included in the VCM
2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
VEHICLES EQUIPPED WITH A PCM AND TCM, REQUIRE A COORDINATED
REPROGRAMMING.
THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS
OUTLINED BY THE INTERGRATED DIAGNOSTIC SYSTEM (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 63.08 and higher. This new calibration
is not included in the VCM 2009.9 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:
(1) Choose all Tests and Calibrations.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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: > 09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle > Page 4846
(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
DISCONNECTING 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 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. Brake gently to a complete
stop and hold foot on brake for at least 10 seconds.
g. Repeat Steps (e-f) a total of three (3) 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
092206A 2006-2008 Explorer, 1.0 Hr.
Mountaineer 2007-2008 Explorer Sport Trac: Check DTCs, Reprogram The PCM And TCM
Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor
Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T >
Control Module, A/T > Component Information > Technical Service Bulletins > Page 4847
View 151-12
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T >
Control Module, A/T > Component Information > Technical Service Bulletins > Page 4848
C199
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission
Seals and Gaskets: Service and Repair 5R55S - Automatic Transaxle/Transmission
Extension Housing Seal
Extension Housing Seal - Rear Wheel Drive (RWD)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4853
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 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.
2. Install the driveshaft. 3. Carry out the transmission fluid level check. See: Service and
Repair/Procedures/Transmission Fluid Level Check
Extension Housing Gasket
Extension Housing Gasket - Rear Wheel Drive (RWD)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4854
Extension Housing Gasket - Rear Wheel Drive (RWD)
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the driveshaft. 3. Support the
transmission with a suitable jack. 4. Remove the transmission support insulator nuts.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4855
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 may fall out
during removal of the extension housing.
Remove the extension housing screws and the extension housing.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4856
8. Remove and discard the extension housing gasket.
Installation
1. Clean the extension housing and install a new extension housing gasket. Make sure that the
parking pawl is installed correctly.
2. NOTE: 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 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4857
3. Install the transmission support insulator and lower the transmission onto the transmission
support insulator.
4. Install the transmission support insulator bolts.
^ Tighten to 90 Nm (66 lb-ft).
5. Install the transmission support insulator nuts.
^ Tighten to 90 Nm (66 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4858
6. Install the driveshaft. 7. Carry out the transmission fluid level check. See: Service and
Repair/Procedures/Transmission Fluid Level Check
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4859
Seals and Gaskets: Service and Repair 6R60 - Automatic Transaxle/Transmission
Output Shaft Seal
Output Shaft Seal
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4860
Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
Rear wheel drive (RWD) vehicles
2. Remove the rear driveshaft.
3. NOTE: The output shaft flange nut has been staked to prevent it from coming loose. Prior to
removing the output shaft flange nut, remove the
stake to prevent damage to the output shaft.
Remove and discard the output shaft flange nut.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4861
4. Remove the output shaft flange.
5. Using the special tools, remove the output shaft seal.
Four wheel drive (4WD) vehicles
6. Remove the transfer case. 7. Using the special tools, remove the output shaft seal.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4862
Installation
RWD vehicles
1. Position a new output shaft seal.
2. Using the special tool, install the output shaft seal.
3. Install the output shaft flange.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4863
4. Install a new output shaft flange nut.
^ Tighten to 60 Nm (44 lb-ft).
^ After installing the new nut, it must be staked at the slots to prevent it from coming loose.
5. Install the rear driveshaft.
4WD vehicles
6. Position the output shaft seal.
7. Using the special tool, install a new output shaft seal.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4864
8. Install the transfer case.
All vehicles
9. Fill and check the transmission fluid.
Manual Control Lever Shaft and Seal
Manual Control Lever Shaft and Seal
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield.
3. Disconnect the selector lever cable end.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4865
4. Remove the transmission fluid fill plug transmission fluid level indicator assembly located on the
passenger side front portion of the transmission
case. Removal of the transmission fluid fill plug will relieve any vacuum that might have built up in
the transmission. This will allow the transmission fluid pan to be easily removed when the bolts are
removed.
5. Remove the transmission fluid pan and allow the transmission fluid to drain.
6. Remove and discard the transmission fluid filter.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4866
7. Remove the transmission fluid pan gasket.
8. CAUTION: Do not pull on the wire harness to disconnect the connector or damage to the
connector will occur.
Disconnect the main transmission electrical harness by twisting the outer shell and pulling back on
the connector.
9. Pull the release tab and pull down on the bulkhead connector retainer.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4867
10. CAUTION: Do not touch the electrical connector pins or the exposed solenoid tabs on the
transmission control module (TCM).
Electrostatic discharge may occur and may cause damage to the mechatronic unit.
With the release tab down, pull the outer shell of the bulkhead electrical connector out of the
transmission control module (TCM).
11. CAUTION: Do not touch the electrical connector pins or the exposed solenoid tabs on the
transmission control module (TCM).
Electrostatic discharge may occur and may cause damage to the mechatronic unit.
Pull the bulkhead electrical connector out of the transmission.
12. NOTE: During removal of the mechatronic, the thermal bypass valve, pump adapter seal and
one or more center support seals may become
dislodged. Save these components for re-use during assembly.
Remove the 11 bolts from the mechatronic assembly and remove the mechatronic assembly.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4868
13. Remove the park pawl abutment.
14. Remove the manual control lever.
1 Remove the roll pin.
2 Slide the manual control lever shaft out of the case.
3 Hold the spacer to keep it from falling out of the case.
4 Remove the manual valve inner detent lever and the park rod as an assembly.
15. Remove and discard the manual control lever seal.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4869
Installation
1. Position a new manual control lever seal in place.
2. Using the special tool, install a new manual control lever shaft seal.
3. Install the manual control lever in the case.
1 Slide the manual control lever in the case.
2 Position the spacer in place while sliding the manual control lever into the spacer.
3 Position the manual valve inner detent lever while sliding the manual control lever and lining up
the roll pin hole.
4 Install the roll pin.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4870
4. Position the manual lever and park rod in place.
^ Push down on the park pawl and position the park rod in place.
5. While holding the park rod down, install the park pawl abutment.
^ Tighten to 10 Nm (89 lb-inch).
6. NOTE: Before installing the mechatronic assembly into the transmission case, verify presence
and correct orientation of the thermal bypass valve,
pump adapter seal and center support seals. Also note that one or more of the center support seals
may have remained in the mechatronic assembly during removal and should be installed into the
transmission case at this time.
Verify the 4 rubber feed tubes for the center support are in place. 1
Black feed tube.
2 Green feed tube.
3 Blue feed tube.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4871
7. Verify the rubber adapter is in place.
8. Verify the thermal bypass valve is in the case.
9. CAUTION: Do not touch the electrical connector pins or the exposed solenoid tabs on the
transmission control module (TCM).
Electrostatic discharge may occur and may cause damage to the mechatronic unit.
Position the mechatronic assembly in place and loosely install the 11 bolts.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4872
1 Align the manual valve and control lever linkage.
10. Tighten the mechatronic bolts in the sequence shown.
^ Tighten to 6 Nm (53 lb-inch).
11. CAUTION: Do not touch the electrical connector pins. Electrostatic discharge may occur and
will cause damage to the mechatronic unit.
With the release tab down and unlocked, push the outer shell of the bulkhead electrical connector
into the transmission. Make sure that the bulkhead connector is fully seated into the TCM.
12. Press up on the tab and lock the outer shell of the bulkhead electrical connector in place.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4873
13. Install a new transmission fluid filter.
14. NOTE: The fluid pan gasket can be reused if not damaged.
Install a new transmission fluid pan gasket if necessary.
15. Install the transmission fluid pan and tighten the bolts in a crisscross pattern.
^ Tighten to 14 Nm (10 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4874
16. Connect the main transmission electrical harness by pushing it in and twisting the outer shell to
lock it in place.
17. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen
for the selector lever cable to click into place. Pull back on the selector lever cable to make sure
that it is locked into the selector lever cable bracket. Also, make sure that the selector lever cable
end is correctly installed onto the ball stud. Pull back on the selector lever cable to make sure that
the selector lever cable end is correctly installed.
Connect the selector lever cable onto the ball stud and move the locking tab down. ^
Listen for the audible click.
^ Pull back on the selector lever cable to make sure that it is correctly installed.
18. Install the selector lever cable shield.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > 5R55S - Automatic Transaxle/Transmission > Page 4875
19. Using the transmission fluid refill procedure, fill and check the transmission fluid.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4881
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4882
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4883
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4884
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4885
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4886
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4887
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4888
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4889
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4890
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4891
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4892
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 4893
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Brake Switch - TCC > Component Information > Diagrams > Page 4894
Brake Switch - TCC: Description and Operation
BRAKE PEDAL POSITION (BPP) SWITCH
Typical BPP Switch
The BPP switch is sometimes referred to as the 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 antilock 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 (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4899
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4900
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4901
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4902
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4903
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4904
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4905
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4906
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4907
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4908
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4909
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4910
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 4911
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4916
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4917
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4918
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4919
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4920
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4921
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4922
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4923
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4924
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4925
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4926
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4927
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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
4928
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Mode Switch, A/T > Component Information > Locations
View 151-15
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4934
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4935
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4936
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4937
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4938
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4939
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4940
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4941
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4942
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4943
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4944
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4945
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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
4946
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 4949
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 (V8-4.6L (2008))
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 4950
Transmission Mode Switch: Service and Repair
Transmission Control (TC) Switch
Transmission Control (TC) Switch
Removal
1. Remove the selector lever knob. 2. Remove the transmission control (TC) switch from the knob.
Installation
1. Install the TC switch into the selector lever knob. 2. Install the selector lever knob.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Locations
Transmission Position Switch/Sensor: Locations
View 151-7
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4954
View 151-11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4957
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4958
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4959
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4960
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4961
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4962
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4963
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4964
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4965
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4966
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4967
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4968
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 4969
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 4970
C167
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4971
Transmission Position Switch/Sensor: Adjustments
Transmission Range (TR) Sensor Adjustment - 5R55S
Adjust
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever 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 digital transmission range (TR) sensor electrical
connector.
4. Disconnect the digital TR sensor electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4972
5. Remove the selector lever cable end from the manual control lever.
6. Remove the outer manual control lever nut and the 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 lb-inch).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4973
9. Install the outer manual lever and nut.
^ Tighten to 48 Nm (35 lb-ft).
10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable
bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable
to make sure that it is locked into the selector lever cable 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 selector lever cable end is correctly installed.
Install the selector lever cable end onto the manual control lever.
11. Reconnect the digital TR sensor electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4974
12. Move the rubber boot back over the TR electrical connector.
13. NOTE: If the selector lever cable shield is loose on the selector lever cable, replace the selector
lever cable shield.
Install the selector lever cable shield.
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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4975
Transmission Position Switch/Sensor: Service and Repair
Digital Transmission Range (TR) Sensor - 5R55S
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by
prying on the side of the selector lever cable shield closest to the boot, then sliding the selector
lever
cable shield away from the boot.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4976
3. Move the rubber boot back to gain access to the digital transmission range (TR) sensor electrical
connector.
4. Disconnect the digital TR sensor electrical connector.
5. Remove the selector lever cable from the manual control lever.
6. Remove the outer manual control lever.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4977
7. Remove the digital TR sensor.
Installation
1. CAUTION: The digital transmission range (TR) 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. ^
Tighten to 8 Nm (71 lb-inch).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4978
3. Install the outer manual lever.
^ Tighten to 48 Nm (35 lb-ft).
4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen
for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that
it is locked into the selector lever cable 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
selector lever cable end is correctly installed.
Install the selector lever cable to the manual control lever.
5. Connect the digital TR sensor electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4979
6. Move the rubber boot back over the TR sensor electrical connector.
7. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector
lever cable shield.
Install the selector lever cable shield.
8. Verify that the selector lever cable is adjusted correctly.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 151-11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4984
Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor
View 151-7
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4985
View 151-11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4986
View 151-11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
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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
4989
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4990
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4991
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4992
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4993
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4994
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4995
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4996
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
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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
4997
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
3 = Splice tape
4 = Harness tape
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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
4998
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
4999
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
5000
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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
5001
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
5002
Transmission Speed Sensor: Connector Views
C193
C143
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
5003
C164
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S
Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor - 5R55S
Intermediate Shaft Speed Sensor
Intermediate Shaft Speed Sensor
Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
Four wheel drive (4WD) vehicles
2. Disconnect the front driveshaft from the transfer case.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S > Page 5006
3. Disconnect the front driveshaft from the front differential.
4. Remove the front driveshaft from the vehicle.
All vehicles
5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield
closest to the boot, then sliding the selector lever
cable shield away from the boot.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S > Page 5007
6. Remove the selector lever cable and selector lever cable 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S > Page 5008
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.
2 Tighten the intermediate shaft speed sensor screw.
^ Tighten to 14 Nm (10 lb-ft).
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 selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable
bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable
to make sure that it is locked into the selector lever cable 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 selector lever cable end is correctly installed.
Install the selector lever cable and selector lever cable bracket. ^
Tighten to 40 Nm (30 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S > Page 5009
4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector
lever cable shield.
Install the selector lever cable shield.
4WD vehicles
5. Install the front driveshaft in the vehicle.
6. Connect the front driveshaft to the transfer case.
^ Tighten to 30 Nm (22 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S > Page 5010
7. Connect the front driveshaft to the front differential.
^ Tighten to 19 Nm (14 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S > Page 5011
Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor - 5R55S
Output Shaft Speed (OSS) Sensor
Output Shaft Speed (OSS) Sensor
Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
Four wheel drive (4WD) vehicles
2. Disconnect the front driveshaft from the transfer case.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S > Page 5012
3. Disconnect the front driveshaft from the front differential.
4. Remove the front driveshaft from the vehicle.
All vehicles
5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield
closest to the boot, then sliding the selector lever
cable shield away from the boot.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S > Page 5013
6. Remove the selector lever cable and selector lever cable bracket.
7. Disconnect the heated oxygen sensor (HO2S) connector from the transmission case.
8. Disconnect the output shaft speed (OSS) sensor electrical connector.
9. Remove the OSS sensor.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S > Page 5014
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.
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 lb-ft).
2. Connect the OSS sensor electrical connector.
3. Connect the HO2S connector to the transmission case.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S > Page 5015
4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable
bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable
to make sure that it is locked into the selector lever cable 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 selector lever cable end is correctly installed.
Install the selector lever cable and selector lever cable bracket. ^
Tighten to 40 Nm (30 lb-ft).
5. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector
lever cable shield.
Install the selector lever cable shield.
4WD vehicles
6. Install the front driveshaft in the vehicle.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S > Page 5016
7. Connect the front driveshaft to the transfer case.
^ Tighten to 30 Nm (22 lb-ft).
8. Connect the front driveshaft to the front differential.
^ Tighten to 19 Nm (14 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S > Page 5017
Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor - 5R55S
Turbine Shaft Speed (TSS) Sensor
Turbine Shaft Speed (TSS) Sensor
Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
Four wheel drive (4WD) vehicles
2. Disconnect the front driveshaft from the transfer case.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S > Page 5018
3. Disconnect the front driveshaft from the front differential.
4. Remove the front driveshaft from the vehicle.
All vehicles
5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield
closest to the boot, then sliding the selector lever
cable shield away from the boot.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S > Page 5019
6. Remove the selector lever cable and selector lever cable 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S > Page 5020
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.
2 Tighten the TSS sensor screw.
^ Tighten to 14 Nm (10 lb-ft).
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 selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable
bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable
to make sure that it is locked into the selector lever cable 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 selector lever cable end is correctly installed.
Install the selector lever cable and selector lever bracket. ^
Tighten to 40 Nm (30 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S > Page 5021
4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new shield.
Install the selector lever cable shield.
4WD vehicles
5. Install the front driveshaft in the vehicle.
6. Connect the front driveshaft to the transfer case.
^ Tighten to 30 Nm (22 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor 5R55S > Page 5022
7. Connect the front driveshaft to the front differential.
^ Tighten to 19 Nm (14 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5027
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5028
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5029
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5030
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5031
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5032
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5033
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5034
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5035
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5036
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5037
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5038
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 5039
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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.
2. Disconnect the brake shift interlock actuator electrical connector.
3. Remove the screw and the brake shift interlock actuator.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift
Interlock Solenoid > Component Information > Service and Repair > Page 5044
Installation
1. Install the brake shift interlock actuator.
2. Connect the brake shift interlock actuator electrical connector.
3. Install the front floor console.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Specifications > 5R55S - Automatic Transaxle/Transmission
Shift Solenoid: Specifications 5R55S - Automatic Transaxle/Transmission
Solenoid Operation Chart
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Specifications > 5R55S - Automatic Transaxle/Transmission > Page 5049
Shift Solenoid: Specifications 6R60 - Automatic Transaxle/Transmission
Solenoid Application Chart
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5052
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5053
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5054
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5055
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5056
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5057
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5058
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5059
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5060
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5061
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5062
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5063
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 5064
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Page 5065
Shift Solenoid: Testing and Inspection
Pinpoint Tests - OSC Equipped Vehicle
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 the following shift solenoid operation information when carrying out Pinpoint Test A.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Page 5066
Solenoid Operation Chart (Part 1)
Solenoid Operation Chart (Part 2)
Shift Solenoid Failure Mode Chart
Failed ON or OFF due to PCM and/or vehicle wiring concerns, solenoid electrically, mechanically
or hydraulically stuck ON or OFF.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Page 5067
SSA, SSB
SSC, SSD
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Page 5068
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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Page 5069
Shift Solenoid: Service and Repair
Solenoid Body Assembly
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Page 5070
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid drain plug
and drain the transmission fluid.
3. NOTE: Clean the area around transmission control solenoid body harness connector to prevent
contamination of the transmission control solenoid
body harness connector.
Disconnect the transmission control solenoid body harness connector.
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
reused.
Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan
gasket.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Page 5071
5. Remove the transmission fluid pan filter.
6. CAUTION: Do not damage the solenoid body connector pins.
Remove the transmission control solenoid body screws and remove the transmission control
solenoid body by pulling down on the transmission control solenoid body and pushing down on the
transmission solenoid body connector from the other side of the case.
Installation
1. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the
O-ring seals with clean transmission fluid.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Page 5072
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 transmission control solenoid body. Tighten the transmission control solenoid body
screws in sequence shown. ^
Tighten to 8 Nm (71 lb-inch).
3. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with
clean transmission fluid.
NOTE: Make sure that the transmission fluid pan filter seals are correctly seated on the
transmission fluid pan filter.
Lubricate the transmission fluid pan seals and install the transmission fluid pan filter. ^
Tighten to 10 Nm (89 lb-inch).
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
reused.
Install the transmission fluid pan and transmission fluid pan gasket and loosely install the
transmission fluid pan screws.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Page 5073
5. Tighten the transmission fluid pan screws in a crisscross sequence.
^ Tighten to 11 Nm (8 lb-ft).
6. CAUTION: Damage will occur to the transmission control solenoid body assembly if the screw is
tightened above the specification.
NOTE: Always install new O-ring seals on transmission control solenoid body harness connector.
NOTE: Clean the area around transmission control solenoid body harness connector to prevent
contamination of the transmission control solenoid body harness 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 control solenoid body harness connector
and connect the connector. ^
Tighten to 5 Nm (44 lb-inch).
7. Fill the transmission.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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. 2. Disconnect the selector lever cable from the selector lever.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever > Page 5078
3. Disconnect the selector lever cable from the selector lever housing.
4. Disconnect the selector lever housing electrical connector.
5. Disconnect the wiring harness from the selector lever housing.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever > Page 5079
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 selector lever cable end is snapped onto the ball stud. Press the
selector lever cable into the selector lever cable bracket and listen for the selector lever cable to
click in place. Pull back on the selector lever cable to make sure that it is locked into the selector
lever cable 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 selector lever cable end is
correctly installed.
1. Install the selector lever housing.
^ Tighten to 9 Nm (80 lb-inch).
2. Connect the wiring harness to the selector lever housing.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever > Page 5080
3. Connect the selector lever housing electrical connector.
4. Install the selector lever cable onto the selector lever housing.
5. Connect the selector lever cable onto the selector lever.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever > Page 5081
6. Install the front floor console.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever > Page 5082
Shifter A/T: Service and Repair Selector Lever Knob
Selector Lever Knob
Selector Lever Knob
Removal
1. Remove the front floor console. 2. Disconnect the transmission control (TC) switch electrical
connector and feed the wire through the selector lever housing.
3. Slide the selector lever knob lower trim cover downward.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever > Page 5083
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 lb-inch).
2. Slide the selector lever knob lower trim cover upward.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever > Page 5084
3. Feed the wire through the selector lever housing and connect the TC switch electrical connector.
4. Install the front floor console.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever > Page 5085
Shifter A/T: Service and Repair Selector Lever Bezel
Selector Lever Bezel
Selector Lever Bezel
Removal
1. Remove the front floor console. 2. Disconnect the transmission control (TC) switch electrical
connector and feed the wire through the selector lever housing.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever > Page 5086
3. Slide the selector lever knob 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 selector lever bezel from the selector lever housing.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever > Page 5087
Installation
1. Install the selector lever bezel onto the selector lever housing.
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 lb-inch).
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever > Page 5088
5. Install the front floor console.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Adjustments > Selector Lever Cable Adjustment - 5R55S
Shift Cable: Adjustments Selector Lever Cable Adjustment - 5R55S
Selector Lever Cable Adjustment - 5R55S
1. With the vehicle in NEUTRAL, position it on a hoist. 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
selector lever cable shield by prying on the side of the selector lever cable shield closest to the
boot, then sliding the selector lever
cable shield away from the boot.
5. Disconnect the selector lever cable end from the manual control lever.
6. Rotate the manual control lever clockwise until the travel stops. Then rotate the manual control
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Adjustments > Selector Lever Cable Adjustment - 5R55S > Page 5094
8. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable
bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable
to make sure that it is locked into the selector lever cable 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 selector lever cable end is correctly installed.
Carry out the following 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 selector lever cable shield is loose on the selector lever cable, install a new selector
lever cable shield.
Install and secure the selector lever 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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Adjustments > Selector Lever Cable Adjustment - 5R55S > Page 5095
Shift Cable: Adjustments Selector Lever Cable Adjustment - 6R60
Selector Lever Cable Adjustment - 6R60
1. With the vehicle in NEUTRAL, position the vehicle on a hoist. 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 selector lever cable shield by prying on the side of the selector lever cable shield closest to the
boot, then sliding the shield away from
the boot.
5. Disconnect the selector lever cable from the manual control lever.
6. Rotate the manual control lever clockwise until the travel stops. Then rotate the manual control
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Adjustments > Selector Lever Cable Adjustment - 5R55S > Page 5096
8. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable
bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable
to make sure that it is locked into the selector lever cable 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 selector lever cable end is correctly installed.
Carry out the following 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 selector lever cable shield is loose on the selector lever cable, install a new selector
lever cable shield.
Install and secure the selector lever cable shield.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Adjustments > Page 5097
Shift Cable: Service and Repair
Selector Lever Cable
Vehicles Equipped with a 6R60 Transmission
Vehicles Equipped with a 6R60 Transmission
Vehicles Equipped with a 5R55S Transmission
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Adjustments > Page 5098
Vehicles Equipped with a 5R55S Transmission
Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist. 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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Adjustments > Page 5099
4. Disconnect the selector lever cable from the selector lever housing.
5. Pull the selector lever cable and grommet through the floorpan.
Vehicles equipped with a 6R60 transmission
6. Remove the selector lever cable shield by prying on the selector lever shield closest to the boot,
then sliding the shield away from the boot.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Adjustments > Page 5100
7. Unlock the lock tab and disconnect the selector lever cable end from the manual control lever.
8. Disconnect the selector lever cable from the selector lever cable bracket and remove the
selector lever cable.
Vehicles equipped with a 5R55S transmission
9. Remove the selector lever cable shield by prying on the side of the selector lever cable shield
closest to the boot, then sliding the shield away from
the boot.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Adjustments > Page 5101
10. Unlock the lock tab and disconnect the selector lever cable end from the manual control lever.
11. Disconnect the selector lever cable from the bracket and remove the selector lever 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 selector lever cable end is snapped onto the ball stud. Press the
selector lever cable into the selector lever cable bracket and listen for the selector lever cable to
click in place. Pull back on the selector lever cable to make sure that it is locked into the selector
lever cable 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 selector lever cable end is
correctly installed.
1. Install the selector lever cable into the selector lever cable bracket.
2. Connect the selector lever cable end onto the manual control lever and lock the lock tab.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Adjustments > Page 5102
3. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector
lever cable shield.
Install and secure the selector lever 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 selector lever cable end is snapped onto the ball stud. Press the
selector lever cable into the selector lever cable bracket and listen for the selector lever cable to
click in place. Pull back on the selector lever cable to make sure that it is locked into the selector
lever cable 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 selector lever cable end is
correctly installed.
4. Install the selector lever cable into the selector lever cable bracket.
5. Connect the selector lever cable end onto the manual control lever.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Adjustments > Page 5103
6. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector
lever cable shield.
Install and secure the selector lever cable shield.
All vehicles
7. Push the selector lever cable and grommet through the floorpan.
8. Connect the selector lever cable onto the selector lever housing.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Adjustments > Page 5104
9. Connect the selector lever cable onto the selector lever.
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 (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5109
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5110
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5111
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5112
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5113
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5114
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5115
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5116
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5117
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5118
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5119
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5120
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5121
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Description and Operation > 5R55S - Automatic Transaxle/Transmission
Torque Converter: Description and Operation 5R55S - Automatic Transaxle/Transmission
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 transmission fluid in motion.
^ The turbine reacts to the transmission fluid motion from the impeller, transferring rotation to the
geartrain through the input shaft.
^ The reactor redirects transmission 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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Description and Operation > 5R55S - Automatic Transaxle/Transmission > Page 5126
Torque Converter: Description and Operation 6R60 - Automatic Transaxle/Transmission
Torque Converter
The torque converter is a 3-element unit containing a 3-plate clutch. The clutch can be controlled
and engaged in any gear 2 to 6. Calibration parameters may be set to allow lockup in a higher gear
only. The clutch is applied by removing fluid pressure from one side of the plate. The torque
converter transmits and multiplies torque. The torque converter includes the following 3 elements: ^
Impeller assembly
^ Turbine assembly
^ Reactor assembly
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.
^ Power is transmitted from the torque converter to the planetary gearsets and other components
through the input shaft.
Torque Converter Clutch
The torque converter clutch is a device that reduces slip in the torque converter and, therefore,
helps to keep fuel consumption to a minimum.
The torque converter clutch is engaged and released by the control system.
Pressure at the torque converter clutch piston is determined by an electronic pressure control
valve.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Testing and Inspection > 5R55S - Automatic Transaxle/Transmission
Torque Converter: Testing and Inspection 5R55S - Automatic Transaxle/Transmission
Stall Speed Chart
Stall Speed Chart
Torque Converter
Torque Converter
1. A new or remanufactured torque converter must be installed if one or more of the following
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 the following 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.
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.
NOTE: The torque converter drain plug and seal are not reusable. If equipped, discard the torque
converter drain plug and seal, then install a new torque converter drain plug assembly.
1. If a new or remanufactured torque converter is not being installed, the following 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 transmission fluid.
3. Observe the color and odor of the transmission fluid. The transmission 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
transmission fluid for signs of antifreeze (gum or
varnish). If particles are present in the transmission 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 transmission fluid into the converter and
agitate by hand. 7. Thoroughly drain the transmission fluid.
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: Transmission Control Systems/Testing and
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Testing and Inspection > 5R55S - Automatic Transaxle/Transmission > Page 5129
Inspection/Component Tests and General Diagnostics/5R55S - Automatic
Transaxle/Transmission/Torque Converter Operation Test
4. Carry out Diagnostic Procedures.
^ Run on-board diagnostics. See On-Board Diagnostics with scan tool. Refer to 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. Refer to Special Testing Procedures. See: Transmission
Control Systems/Testing and Inspection/Component Tests and General Diagnostics/5R55S Automatic Transaxle/Transmission/Special Testing Procedures
^ Carry out the Stall Speed Test. See: Transmission Control Systems/Testing and
Inspection/Component Tests and General Diagnostics/5R55S - Automatic
Transaxle/Transmission/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.
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. See On-Board Diagnostics with Scan Tool. Refer
to Diagnostics. Check for DTCs. Refer to the Diagnostic Trouble
Code (DTC) Charts. See: Transmission Control Systems/Testing and Inspection/Initial Inspection
and Diagnostic Overview 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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Testing and Inspection > 5R55S - Automatic Transaxle/Transmission > Page 5130
Torque Converter: Testing and Inspection 6R60 - Automatic Transaxle/Transmission
Torque Converter
Torque Converter
1. A new or remanufactured torque converter must be installed if one or more of the following
statements is true:
^ A torque converter malfunction has been determined based on complete diagnostic procedures.
^ Converter rivets, impeller hub or bushing are damaged.
^ Discoloration (due to overheating).
^ Evidence of transmission assembly or fluid contamination due to the following 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.
Torque Converter Contamination Inspection
Torque Converter Contamination Inspection
CAUTION: Do not use water-based cleaners or mineral spirits to clean or flush the torque converter
or transmission, damage will occur. Use only clean automatic transmission fluid designated for the
transmission and converter being serviced.
1. If a new or remanufactured torque converter is not being installed, the following 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. NOTE: The factory fill fluid is red.
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 (specks of any kind). Examine the
transmission fluid level indicator for signs of antifreeze
(gum or varnish). If particles are present in the transmission fluid, 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 transmission fluid into the converter and
agitate by hand. 7. Thoroughly drain the transmission fluid.
Torque Converter Diagnosis
Torque Converter Diagnosis
Prior to torque converter installation, 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 torque converter.
Begin with the normal diagnostic procedures as follows: 1. Preliminary inspection. 2. Know and
understand the customer's concern. 3. Verify the condition - carry out the torque converter
operation test. See: 5R55S - Automatic Transaxle/Transmission/Torque Converter Operation
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Testing and Inspection > 5R55S - Automatic Transaxle/Transmission > Page 5131
Test
4. Carry out diagnostic procedures. See: Transmission Control Systems/Testing and
Inspection/Symptom Related Diagnostic Procedures/Diagnosis
By Symptom ^
Carry out on-board diagnostics. Refer to Diagnostics. Repair all non-transmission related DTCs first.
- Repair all transmission-related DTCs.
- Rerun on-board diagnostics to verify repair.
^ Carry out Stall Speed Test. Refer to Special Testing Procedures. See: Transmission Control
Systems/Testing and Inspection/Component Tests and General Diagnostics/5R55S - Automatic
Transaxle/Transmission/Stall Speed Test
^ Carry out Diagnostic Routines. Refer to Diagnosis By Symptom. See: Transmission Control
Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Diagnosis By Symptom
Use the Diagnosis by Symptom 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 repair as required before changing the
torque converter.
Torque Converter Operation Test
The Torque Converter Operation Test verifies that the torque converter clutch (TCC) control
system and the torque converter are operating correctly. 1. Carry out Quick Test with scan tool.
Refer to Computers and Control Systems. Check for DTCs. 2. Connect a scan tool to the vehicle.
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 speed of about 56 km/h (35 mph) in 5th gear for 10 seconds. 5. Release the accelerator
pedal and monitor the scan tool TP voltage to approximately 1.25 volts or 30% throttle. 6. Monitor
the TCC and engine speed PID. The TCC should release and engine rpms should increase before
the 5-4 shift occurs.
NOTE: The following is a list of common vehicle concerns that have been misdiagnosed as TCC
shudder. For diagnosis of the following items, refer to Computers and Control Systems.
^ Spark plugs - check for cracks, high resistance or broken insulators
^ Plug wires
^ Fuel injector - filter may be plugged
^ Fuel contamination - engine driveability concerns
^ EGR valve - valve may let in too much exhaust gas and cause engine to run lean
^ Vacuum leak - engine will not get correct air/fuel mixture
^ Manifold absolute pressure (MAP)/mass air flow (MAF) sensor - incorrect air/fuel mixture
^ Heated oxygen sensor (HO2S) - too rich/lean air/fuel mixture
^ Fuel pressure - may be too low
^ Engine mounts - loose/damaged mounts can cause vibration concerns
^ Axle joints - check for vibration
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Specifications
Torque Converter Clutch Solenoid: Specifications
Solenoid Application Chart
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5137
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5138
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5139
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5140
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5141
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5142
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5143
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5144
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5145
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5146
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5147
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5148
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5149
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Page 5150
Torque Converter Clutch Solenoid: Service and Repair
Solenoid Body Assembly
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Page 5151
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid drain plug
and drain the transmission fluid.
3. NOTE: Clean the area around transmission control solenoid body harness connector to prevent
contamination of the transmission control solenoid
body harness connector.
Disconnect the transmission control solenoid body harness connector.
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
reused.
Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan
gasket.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Page 5152
5. Remove the transmission fluid pan filter.
6. CAUTION: Do not damage the solenoid body connector pins.
Remove the transmission control solenoid body screws and remove the transmission control
solenoid body by pulling down on the transmission control solenoid body and pushing down on the
transmission solenoid body connector from the other side of the case.
Installation
1. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the
O-ring seals with clean transmission fluid.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Page 5153
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 transmission control solenoid body. Tighten the transmission control solenoid body
screws in sequence shown. ^
Tighten to 8 Nm (71 lb-inch).
3. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with
clean transmission fluid.
NOTE: Make sure that the transmission fluid pan filter seals are correctly seated on the
transmission fluid pan filter.
Lubricate the transmission fluid pan seals and install the transmission fluid pan filter. ^
Tighten to 10 Nm (89 lb-inch).
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
reused.
Install the transmission fluid pan and transmission fluid pan gasket and loosely install the
transmission fluid pan screws.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Page 5154
5. Tighten the transmission fluid pan screws in a crisscross sequence.
^ Tighten to 11 Nm (8 lb-ft).
6. CAUTION: Damage will occur to the transmission control solenoid body assembly if the screw is
tightened above the specification.
NOTE: Always install new O-ring seals on transmission control solenoid body harness connector.
NOTE: Clean the area around transmission control solenoid body harness connector to prevent
contamination of the transmission control solenoid body harness 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 control solenoid body harness connector
and connect the connector. ^
Tighten to 5 Nm (44 lb-inch).
7. Fill the transmission.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Technical Service Bulletins > Recalls for Transmission Cooler: > 07S56 > Aug > 07 > Recall - A/T
Cooler Line Leakage/Fire Potential
Technical Service Bulletin # 07S56 Date: 070822
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Technical Service Bulletins > Recalls for Transmission Cooler: > 07S56 > Aug > 07 > Recall - A/T
Cooler Line Leakage/Fire Potential > Page 5163
Attachment I - Administrative Information
OASIS ACTIVATED?
Yes. OASIS will be activated by August 22, 2007.
FSA VIN LIST ACTIVATED?
Yes. Available through the website by August 22, 2007. Owner names and addresses will be
available by September 7, 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 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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Technical Service Bulletins > Recalls for Transmission Cooler: > 07S56 > Aug > 07 > Recall - A/T
Cooler Line Leakage/Fire Potential > Page 5164
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.
OWNER REFUNDS
Refunds are not authorized for this program.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
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 prior 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
LABOR ALLOWANCES
PARTS REQUIREMENTS / ORDERING INFORMATION
Parts are not required for this repair.
Attachment III - Technical Information
1. Lift vehicle and locate the transmission fluid cooler line attachment bolt on the left side of the
transmission. (See illustration.)
NOTE:
If cooler lines are leaking transmission fluid at the transmission attachment point, call Special
Service Support Center.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Technical Service Bulletins > Recalls for Transmission Cooler: > 07S56 > Aug > 07 > Recall - A/T
Cooler Line Leakage/Fire Potential > Page 5165
2. Tighten Transmission Fluid Cooler Line Attachment bolt to 25 Nm (18 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Technical Service Bulletins > Recalls for Transmission Cooler: > 07S56 > Aug > 07 > Recall - A/T
Cooler Line Leakage/Fire Potential > Page 5166
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Technical Service Bulletins > Recalls for Transmission Cooler: > 07S56 > Aug > 07 > Recall - A/T
Cooler Line Leakage/Fire Potential > Page 5167
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 07S56 >
Aug > 07 > Recall - A/T Cooler Line Leakage/Fire Potential
Technical Service Bulletin # 07S56 Date: 070822
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 07S56 >
Aug > 07 > Recall - A/T Cooler Line Leakage/Fire Potential > Page 5173
Attachment I - Administrative Information
OASIS ACTIVATED?
Yes. OASIS will be activated by August 22, 2007.
FSA VIN LIST ACTIVATED?
Yes. Available through the website by August 22, 2007. Owner names and addresses will be
available by September 7, 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 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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 07S56 >
Aug > 07 > Recall - A/T Cooler Line Leakage/Fire Potential > Page 5174
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.
OWNER REFUNDS
Refunds are not authorized for this program.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
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 prior 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
LABOR ALLOWANCES
PARTS REQUIREMENTS / ORDERING INFORMATION
Parts are not required for this repair.
Attachment III - Technical Information
1. Lift vehicle and locate the transmission fluid cooler line attachment bolt on the left side of the
transmission. (See illustration.)
NOTE:
If cooler lines are leaking transmission fluid at the transmission attachment point, call Special
Service Support Center.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 07S56 >
Aug > 07 > Recall - A/T Cooler Line Leakage/Fire Potential > Page 5175
2. Tighten Transmission Fluid Cooler Line Attachment bolt to 25 Nm (18 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 07S56 >
Aug > 07 > Recall - A/T Cooler Line Leakage/Fire Potential > Page 5176
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 07S56 >
Aug > 07 > Recall - A/T Cooler Line Leakage/Fire Potential > Page 5177
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Specifications > Mechanical Specifications
Transmission Cooler: Mechanical Specifications
General Specifications
General Specifications
Torque Specifications
Torque Specifications
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Specifications > Mechanical Specifications > Page 5180
Transmission Cooler: Capacity Specifications
Material
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Specifications > Mechanical Specifications > Page 5181
Transmission Cooler: Fluid Type Specifications
Material
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
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
Inspection and Verification
When transmission fluid leakage is found in the transmission fluid cooler, install a new transmission
fluid cooler.
When there is evidence of transmission assembly or transmission fluid contamination due to the
following transmission failure modes, install a new transmission fluid cooler. ^
Major metallic failure
^ Multiple clutches or clutch plate failure
^ Sufficient component wear which results in metallic contamination
If the fault is not visually evident, GO to Symptom Chart - Transmission Cooling or GO to Symptom
Chart - Noise, Vibration and Harshness (NVH). See: Symptom Related Diagnostic Procedures
See: Symptom Related Diagnostic Procedures/Symptom Chart - Noise, Vibration and Harshness
(NVH)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5184
Transmission Cooler: Symptom Related Diagnostic Procedures
Symptom Chart - Transmission Cooling
Symptom Chart - Transmission Cooling
Symptom Chart - Transmission Cooling
Symptom Chart - Noise, Vibration and Harshness (NVH)
Symptom Chart - Noise, Vibration and Harshness (NVH)
NOTE: Noise, vibration and harshness (NVH) symptoms should be identified using the diagnostic
tools that are available. For a list of these tools, an explanation of their uses and a glossary of
common terms, refer to Vehicle/Testing and inspection. Since it is possible any one of multiple
systems may be the cause of a symptom, it may be necessary to use a process of elimination type
of diagnostic approach to pinpoint the responsible system. If this is not the causal system for the
symptom, refer back to Vehicle/Testing and inspection for the next likely system and continue
diagnosis.
Symptom Chart - Noise, Vibration and Harshness (NVH)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5185
Transmission Cooler: Component Tests and General Diagnostics
Transmission Fluid Cooler
CAUTION: Whenever a transmission has been disassembled to install new parts, the transmission
fluid cooler and transmission fluid cooler tubes must be cleaned and backflushed. Use a torque
converter/oil cooler cleaner.
NOTE: Cleaning and backflushing the transmission fluid cooling system, along with following all the
normal cleaning and inspection procedures during disassembly and reassembly, will keep
contaminants from entering the transmission, 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 into use.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Transmission Fluid Cooler Backflushing and Cleaning
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. Failure to follow these instructions
may result in transmission failure.
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. ^
Connect the cleaner tank pressure line to the steel transmission cooler return tube (longest tube).
^ Connect a tank return hose to the steel transmission cooler pressure tube (shorter tube). 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 tube.
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 tube.
Transmission Fluid Cooler Flow Test - 5R55S
Transmission Fluid Cooler Flow Test - 5R55S
1. Refer to Automatic Transaxle/Transmission - 5R55S.
6R60 - Automatic Transaxle/Transmission
Transmission Fluid Cooler Backflushing and Cleaning
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Procedures > Page 5188
CAUTION: When internal damage occurs in the transmission, metal particles and clutch plate
material can travel into the torque converter and the transmission fluid cooler. These contaminates
are a major cause of recurring transmission concerns. To prevent further concerns, remove these
contaminates from the transmission fluid cooler tubes and install a new transmission fluid cooler
before placing the transmission in use.
CAUTION: Do not attempt to install an in-line transmission fluid filter on this vehicle, damage to the
transmission fluid cooling system or transmission could occur.
1. Install a new transmission fluid cooler if any transmission fluid leaks are indicated or a major
metallic failure is indicated. 2. Using a suitable torque converter/fluid cooler cleaner, flush the
transmission fluid cooler and tubes.
3. NOTE: Rubber hoses must be attached to the ends of the transmission fluid cooler tubes, to aid
in connecting them to the cleaner.
Connect the cleaner pressure and return lines appropriately in the following sequence. 1
Connect the pressure line to the transmission fluid cooler inlet tube.
2 Connect the return line to the transmission fluid cooler outlet tube.
3 Place the outlet end of the return line in the transmission fluid tank reservoir.
4. NOTE: Cycling the fluid pump ON and OFF will help dislodge contaminants in the cooler system.
Switch the fluid pump ON. Allow the transmission fluid to circulate a minimum of 5 minutes.
5. Switch the fluid pump OFF. 6. Disconnect the cleaner pressure line at the transmission fluid
cooler tube. 7. Using compressed air, blow through the transmission fluid cooler inlet tube until all
transmission fluid is removed. 8. Remove the rubber hoses from the transmission fluid cooler
tubes.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Procedures > Page 5189
Transmission Cooler: Removal and Replacement
Auxiliary Transmission Fluid Cooler
Removal
Mountaineer
1. Remove the grille fasteners and the grille.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Procedures > Page 5190
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Procedures > Page 5191
6. Remove the upper transmission fluid cooler bolt.
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 lb-inch).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Procedures > Page 5192
2. Install the upper transmission fluid cooler bolt.
^ Tighten to 7 Nm (62 lb-inch).
3. NOTE: Clean the transmission cooler tube stems with degreaser prior to installing the hoses.
Using new hoses and clamps, install the new transmission fluid cooler hoses.
4. Push the lower air deflector back into place.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Procedures > Page 5193
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 the transmission fluid to the correct level using clean transmission fluid and inspect the leaks.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Locations
View 151-15
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5202
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5203
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5204
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5205
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5206
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5207
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5208
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5209
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5210
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5211
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5212
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5213
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5214
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Description and Operation > Transmission Control (TC) Switch > Page 5217
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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Description and Operation > Page 5218
Transmission Mode Switch: Service and Repair
Transmission Control (TC) Switch
Transmission Control (TC) Switch
Removal
1. Remove the selector lever knob. 2. Remove the transmission control (TC) switch from the knob.
Installation
1. Install the TC switch into the selector lever knob. 2. Install the selector lever knob.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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)
Transmission Support Insulator - Rear Wheel Drive (RWD)
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Support the transmission with a
transmission jack. 3. Remove the 2 transmission support insulator nuts.
4. Remove the 2 transmission support insulator bolts.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Service and Repair > Page 5222
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.
2. Install the 2 transmission support insulator bolts.
^ Tighten to 90 Nm (66 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Service and Repair > Page 5223
3. Install the 2 transmission support insulator nuts.
^ Tighten to 90 Nm (66 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations
Transmission Position Switch/Sensor: Locations
View 151-7
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 5227
View 151-11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5230
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5231
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5232
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5233
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5234
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5235
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5236
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5237
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5238
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5239
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5240
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5241
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5242
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5243
C167
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Page 5244
Transmission Position Switch/Sensor: Adjustments
Transmission Range (TR) Sensor Adjustment - 5R55S
Adjust
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever 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 digital transmission range (TR) sensor electrical
connector.
4. Disconnect the digital TR sensor electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Page 5245
5. Remove the selector lever cable end from the manual control lever.
6. Remove the outer manual control lever nut and the 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 lb-inch).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Page 5246
9. Install the outer manual lever and nut.
^ Tighten to 48 Nm (35 lb-ft).
10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable
bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable
to make sure that it is locked into the selector lever cable 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 selector lever cable end is correctly installed.
Install the selector lever cable end onto the manual control lever.
11. Reconnect the digital TR sensor electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Page 5247
12. Move the rubber boot back over the TR electrical connector.
13. NOTE: If the selector lever cable shield is loose on the selector lever cable, replace the selector
lever cable shield.
Install the selector lever cable shield.
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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Page 5248
Transmission Position Switch/Sensor: Service and Repair
Digital Transmission Range (TR) Sensor - 5R55S
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by
prying on the side of the selector lever cable shield closest to the boot, then sliding the selector
lever
cable shield away from the boot.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Page 5249
3. Move the rubber boot back to gain access to the digital transmission range (TR) sensor electrical
connector.
4. Disconnect the digital TR sensor electrical connector.
5. Remove the selector lever cable from the manual control lever.
6. Remove the outer manual control lever.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Page 5250
7. Remove the digital TR sensor.
Installation
1. CAUTION: The digital transmission range (TR) 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. ^
Tighten to 8 Nm (71 lb-inch).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Page 5251
3. Install the outer manual lever.
^ Tighten to 48 Nm (35 lb-ft).
4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen
for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that
it is locked into the selector lever cable 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
selector lever cable end is correctly installed.
Install the selector lever cable to the manual control lever.
5. Connect the digital TR sensor electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Page 5252
6. Move the rubber boot back over the TR sensor electrical connector.
7. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector
lever cable shield.
Install the selector lever cable shield.
8. Verify that the selector lever cable is adjusted correctly.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test
Port, A/T > Component Information > Locations > Pressure Test - PC A, PC B - 5R55S
Transmission Pressure Test Port: Locations Pressure Test - PC A, PC B - 5R55S
Pressure Test - PC A, PC B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test
Port, A/T > Component Information > Locations > Pressure Test - PC A, PC B - 5R55S > Page 5257
Transmission Pressure Test Port: Locations Pressure Test - PC C - 5R55S
Pressure Test - PC C
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor
View 151-11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 5262
Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor
View 151-7
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 5263
View 151-11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 5264
View 151-11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5267
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5268
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5269
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5270
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5271
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5272
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5273
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5274
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5275
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5276
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5277
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5278
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5279
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5280
Transmission Speed Sensor: Connector Views
C193
C143
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5281
C164
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S
Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor - 5R55S
Intermediate Shaft Speed Sensor
Intermediate Shaft Speed Sensor
Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
Four wheel drive (4WD) vehicles
2. Disconnect the front driveshaft from the transfer case.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5284
3. Disconnect the front driveshaft from the front differential.
4. Remove the front driveshaft from the vehicle.
All vehicles
5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield
closest to the boot, then sliding the selector lever
cable shield away from the boot.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5285
6. Remove the selector lever cable and selector lever cable 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5286
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.
2 Tighten the intermediate shaft speed sensor screw.
^ Tighten to 14 Nm (10 lb-ft).
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 selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable
bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable
to make sure that it is locked into the selector lever cable 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 selector lever cable end is correctly installed.
Install the selector lever cable and selector lever cable bracket. ^
Tighten to 40 Nm (30 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5287
4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector
lever cable shield.
Install the selector lever cable shield.
4WD vehicles
5. Install the front driveshaft in the vehicle.
6. Connect the front driveshaft to the transfer case.
^ Tighten to 30 Nm (22 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5288
7. Connect the front driveshaft to the front differential.
^ Tighten to 19 Nm (14 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5289
Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor - 5R55S
Output Shaft Speed (OSS) Sensor
Output Shaft Speed (OSS) Sensor
Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
Four wheel drive (4WD) vehicles
2. Disconnect the front driveshaft from the transfer case.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5290
3. Disconnect the front driveshaft from the front differential.
4. Remove the front driveshaft from the vehicle.
All vehicles
5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield
closest to the boot, then sliding the selector lever
cable shield away from the boot.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5291
6. Remove the selector lever cable and selector lever cable bracket.
7. Disconnect the heated oxygen sensor (HO2S) connector from the transmission case.
8. Disconnect the output shaft speed (OSS) sensor electrical connector.
9. Remove the OSS sensor.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5292
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.
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 lb-ft).
2. Connect the OSS sensor electrical connector.
3. Connect the HO2S connector to the transmission case.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5293
4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable
bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable
to make sure that it is locked into the selector lever cable 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 selector lever cable end is correctly installed.
Install the selector lever cable and selector lever cable bracket. ^
Tighten to 40 Nm (30 lb-ft).
5. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector
lever cable shield.
Install the selector lever cable shield.
4WD vehicles
6. Install the front driveshaft in the vehicle.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5294
7. Connect the front driveshaft to the transfer case.
^ Tighten to 30 Nm (22 lb-ft).
8. Connect the front driveshaft to the front differential.
^ Tighten to 19 Nm (14 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5295
Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor - 5R55S
Turbine Shaft Speed (TSS) Sensor
Turbine Shaft Speed (TSS) Sensor
Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
Four wheel drive (4WD) vehicles
2. Disconnect the front driveshaft from the transfer case.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5296
3. Disconnect the front driveshaft from the front differential.
4. Remove the front driveshaft from the vehicle.
All vehicles
5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield
closest to the boot, then sliding the selector lever
cable shield away from the boot.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5297
6. Remove the selector lever cable and selector lever cable 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5298
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.
2 Tighten the TSS sensor screw.
^ Tighten to 14 Nm (10 lb-ft).
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 selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable
bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable
to make sure that it is locked into the selector lever cable 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 selector lever cable end is correctly installed.
Install the selector lever cable and selector lever bracket. ^
Tighten to 40 Nm (30 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5299
4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new shield.
Install the selector lever cable shield.
4WD vehicles
5. Install the front driveshaft in the vehicle.
6. Connect the front driveshaft to the transfer case.
^ Tighten to 30 Nm (22 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft Speed Sensor - 5R55S > Page 5300
7. Connect the front driveshaft to the front differential.
^ Tighten to 19 Nm (14 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5305
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5306
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5307
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5308
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5309
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5310
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5311
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5312
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5313
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5314
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5315
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5316
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5317
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Locations
Valve Body: Locations
Main Control Valve Body
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Locations > Page 5321
Valve Body: Diagrams
Main Control Valve Body
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Locations > Page 5322
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Solenoid Body Assembly
Solenoid Body Assembly
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 5325
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid drain plug
and drain the transmission fluid.
3. NOTE: Clean the area around transmission control solenoid body harness connector to prevent
contamination of the transmission control solenoid
body harness connector.
Disconnect the transmission control solenoid body harness connector.
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
reused.
Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan
gasket.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 5326
5. Remove the transmission fluid pan filter.
6. CAUTION: Do not damage the solenoid body connector pins.
Remove the transmission control solenoid body screws and remove the transmission control
solenoid body by pulling down on the transmission control solenoid body and pushing down on the
transmission solenoid body connector from the other side of the case.
Installation
1. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the
O-ring seals with clean transmission fluid.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 5327
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 transmission control solenoid body. Tighten the transmission control solenoid body
screws in sequence shown. ^
Tighten to 8 Nm (71 lb-inch).
3. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with
clean transmission fluid.
NOTE: Make sure that the transmission fluid pan filter seals are correctly seated on the
transmission fluid pan filter.
Lubricate the transmission fluid pan seals and install the transmission fluid pan filter. ^
Tighten to 10 Nm (89 lb-inch).
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
reused.
Install the transmission fluid pan and transmission fluid pan gasket and loosely install the
transmission fluid pan screws.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 5328
5. Tighten the transmission fluid pan screws in a crisscross sequence.
^ Tighten to 11 Nm (8 lb-ft).
6. CAUTION: Damage will occur to the transmission control solenoid body assembly if the screw is
tightened above the specification.
NOTE: Always install new O-ring seals on transmission control solenoid body harness connector.
NOTE: Clean the area around transmission control solenoid body harness connector to prevent
contamination of the transmission control solenoid body harness 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 control solenoid body harness connector
and connect the connector. ^
Tighten to 5 Nm (44 lb-inch).
7. Fill the transmission.
Main Control Valve Body
Main Control Valve Body
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 5329
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 5330
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 5331
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. If equipped, remove the transmission fluid
drain plug and drain the transmission fluid.
3. NOTE: Clean the area around the transmission solenoid body harness connector to prevent
contamination of the transmission control solenoid
body harness connector.
Disconnect the transmission control solenoid body harness connector.
4. NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
reused.
Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan
gasket.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 5332
5. Remove the transmission fluid pan filter.
6. Remove the reverse servo assembly screws and the reverse servo assembly.
7. Remove the transmission control solenoid body screws and the transmission control solenoid
body.
8. Remove the manual control valve detent spring.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 5333
9. Remove the main control valve body screws and 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 main control
valve body screws.
1 Install the short main control valve body screw.
2 Install the main control valve body screw with the larger head.
3 Install the remaining main control valve body screws.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 5334
3. Remove the special tools and loosely install the main control valve body screw.
4. Tighten the main control valve body screws in the sequence shown.
^ Tighten to 10 Nm (89 lb-inch).
5. Install the manual control valve detent spring.
^ Tighten to 10 Nm (89 lb-inch).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 5335
6. Install the reverse servo assembly. Tighten the reverse servo assembly screws in 2 stages, in
the sequence shown.
^ Stage 1: Tighten to 5 Nm (44 lb-inch).
^ Stage 2: Tighten to 11 Nm (8 lb-ft).
7. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the
O-ring seals with clean 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 transmission control solenoid body. Tighten the transmission control solenoid body
screws in the sequence shown. ^
Tighten to 8 Nm (71 lb-inch).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 5336
9. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with
clean transmission fluid.
NOTE: Make sure that the transmission fluid filter seals are correctly seated on the transmission
fluid filter.
Lubricate the transmission fluid filter seals and install the transmission fluid pan filter. ^
Tighten to 10 Nm (89 lb-inch).
10. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
reused.
Install the transmission fluid pan gasket on the transmission fluid pan.
11. Install the transmission fluid pan and transmission fluid pan gasket and loosely install the
transmission fluid pan screws.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 5337
12. Tighten the transmission fluid pan screws in a crisscross sequence.
^ Tighten to 11 Nm (8 lb-ft).
13. CAUTION: Damage will occur to the transmission control solenoid body assembly if the screw
is tightened above specification.
NOTE: Always install new O-ring seals on the transmission control solenoid body harness
connector.
NOTE: Clean the area around transmission control solenoid body harness connector to prevent
contamination of the transmission control solenoid body harness 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 control solenoid body harness connector
and connect the transmission control solenoid body harness connector. ^
Tighten to 5 Nm (44 lb-inch).
14. Fill the transmission.
6R60 - Automatic Transaxle/Transmission
Mechatronic Assembly
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 5338
Removal
NOTE: If a new or the existing mechatronic assembly is installed, the transmission control module
(TCM) will need to be reflashed to the latest level calibration available.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. CAUTION: Do not pull on the wire harness to disconnect the connector or damage to the
connector will occur.
Disconnect the main transmission electrical harness by twisting the outer shell and pulling back on
the connector.
3. Remove the transmission fluid fill plug transmission fluid level indicator assembly located on the
passenger side front portion of the transmission
case. Removal of the transmission fluid fill plug will relieve any vacuum that might have built up in
the transmission. This will allow the transmission fluid pan to be easily removed when the bolts are
removed.
4. Remove the transmission fluid pan and allow the transmission fluid to drain.
5. Remove the transmission fluid pan gasket.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 5339
6. Remove and discard the transmission fluid filter.
7. Pull the release tab and pull down on the bulkhead connector retainer.
8. CAUTION: Do not touch the electrical connector pins or the exposed solenoid tabs on the
transmission control module (TCM).
Electrostatic discharge may occur and may cause damage to the mechatronic unit.
With the release tab down, pull the outer shell of the bulkhead electrical connector out of the TCM.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 5340
9. CAUTION: Do not touch the electrical connector pins or the exposed solenoid tabs on the
transmission control module (TCM).
Electrostatic discharge may occur and may cause damage to the mechatronic unit.
Pull the bulkhead electrical connector out of the transmission.
10. NOTE: During removal of the mechatronic, the thermal bypass valve, pump adapter seal and
one or more center support seals may become
dislodged. Save these components for re-use during assembly.
Remove the 11 bolts from the mechatronic assembly and remove the mechatronic assembly.
Installation
NOTE: Before reinstalling the mechatronic assembly into the transmission case, verify presence
and correct orientation of the thermal bypass valve, pump adapter seal and center support seals.
Also note that one or more of the center support seals may have remained in the mechatronic
assembly during removal and should be installed into the transmission case at this time.
1. Verify the 4 rubber feed tubes for the center support are in place.
1 Black feed tube.
2 Green feed tube.
3 Blue feed tube.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 5341
2. Verify the rubber adapter is in place.
3. Verify the thermal bypass valve is in the case.
4. Position the mechatronic assembly in place and loosely install the 11 bolts.
1 Align the manual valve and control lever linkage.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 5342
5. Tighten the mechatronic bolts in the sequence shown.
^ Tighten to 6 Nm (53 lb-inch).
6. CAUTION: Do not touch the electrical connector pins or the exposed solenoid tabs on the
transmission control module (TCM).
Electrostatic discharge may occur and may cause damage to the mechatronic unit.
With the release tab down and unlocked, push the outer shell of the bulkhead electrical connector
into the transmission. Make sure that the bulkhead connector is fully seated into the TCM.
7. Press up on the tab and lock the outer shell of the bulkhead electrical connector in place. Make
sure that the locking tab is securely locked.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 5343
8. Install a new transmission fluid filter.
9. NOTE: The transmission fluid pan gasket can be reused if not damaged.
Install a new transmission fluid pan gasket if required.
10. Install the transmission fluid pan and tighten the bolts in a crisscross pattern.
^ Tighten to 14 Nm (10 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 5344
11. Connect the main transmission electrical harness by pushing it in and twisting the outer shell to
lock it in place.
12. Using the transmission fluid refill procedure, fill the transmission with clean transmission fluid.
13. If a new or the existing mechatronic assembly is installed, the TCM will need to be reflashed to
the latest level calibration available.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 5345
Valve Body: Overhaul
Main Control Valve Body
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 5346
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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 5347
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, carry out the following: ^
Inspect all valve and plug bores for scoring or burrs
^ Check all fluid passages for obstructions
^ Inspect all valves and plugs for burrs
^ Inspect all mating surfaces for burrs or 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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 5348
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 lb-inch).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 5357
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 5363
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Specifications > Capacity Specifications > Page 5373
Fluid - Differential: Fluid Type Specifications
Differential Fluid Type
Type ................................................................................................................................ SAE
75W-140 High Performance Synthetic Rear Axle Lubricant
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Specifications > Page 5374
Fluid - Differential: Service and Repair
Differential Draining and Filling
Fluid Drain and Fill
1. Remove both the fill plug and the drain plug.
^ Drain the axle assembly.
2. Clean and install the drain plug.
^ Tighten to 34 Nm (25 lb-ft).
3. Fill the axle with 1.65L (3.5 pt) of axle lubricant to the bottom of the fill plug hole. 4. Clean and
install the fill plug.
^ Tighten to 34 Nm (25 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential
Output Shaft Bearing > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential
Differential Output Shaft Bearing: Service and Repair Ford 8.8-Inch Ring Gear Rear Drive
Axle/Differential
Stub Shaft Pilot Bearing and Seal
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential
Output Shaft Bearing > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential
> Page 5380
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.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential
Output Shaft Bearing > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential
> Page 5381
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.
6. Install the halfshaft assembly.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential
Output Shaft Bearing > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential
> Page 5382
Differential Output Shaft Bearing: Service and Repair Dana 30 Front Drive Axle/Differential
Stub Shaft Pilot Bearing and Seal
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential
Output Shaft Bearing > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential
> Page 5383
Removal
Both sides
1. Remove the halfshafts.
Right side
2. Remove the axle shaft.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential
Output Shaft Bearing > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential
> Page 5384
Both sides
3. Using the special tool and a suitable slide hammer, remove the stub shaft oil seals.
4. Using the special tool and a slide hammer, remove the stub shaft pilot bearings.
5. Clean the bearing and seal surfaces of any foreign material.
Installation
Right side
1. Using the special tools, install the stub shaft pilot bearing.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential
Output Shaft Bearing > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential
> Page 5385
2. Using the special tools, install the stub shaft oil seals.
3. Install the axle shaft.
Left side
4. Using the special tools, install the stub shaft bearing.
5. Using the special tools, install the stub shaft seal.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential
Output Shaft Bearing > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential
> Page 5386
Both sides
6. Refill the front drive axle to the correct level with lubricant. 7. Install the halfshafts.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential
Pinion Flange: Service and Repair Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential
Drive Pinion Flange and Drive Pinion Seal
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential > Page 5391
Removal
1. CAUTION: The color on the rear face of the drive pinion nut is critical to this repair. Use the
same color new drive pinion nut for
installation. If a new collapsible spacer must be installed for pinion bearing preload reduction, install
the nut supplied with the new spacer kit or damage to the component may occur.
With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the rear wheel brake disc.
3. Remove the rear driveshaft. 4. Install a Nm (lb-inch) torque wrench on the pinion nut and record
the torque necessary to maintain rotation of the drive pinion gear through several
revolutions.
CAUTION: The color on the rear face of the drive pinion nut is critical to this repair. Use the same
color new drive pinion nut for installation or damage to the component may occur.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential > Page 5392
5. Using the special tool to hold the pinion flange, remove and discard the pinion nut.
6. Index-mark the pinion flange and drive pinion gear to maintain initial balance during installation.
7. Using the special tool, remove the pinion flange.
8. 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential > Page 5393
Installation
1. If removed, lubricate the lips of the new drive pinion seal with grease.
2. NOTE: If the drive pinion seal becomes misaligned during installation, remove the drive pinion
seal and install a new drive pinion seal.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential > Page 5394
7. CAUTION: The color on the rear face of the drive pinion nut is critical to this repair. Use the
same color new drive pinion nut for
installation or damage to the component may occur.
Select the new pinion nut for installation. Install and hand-tighten the pinion nut.
8.8 In. Pinion Nut
8. 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 or
component damage may occur. Install the new pinion nut that is included in the collapsible spacer
kit.
Tighten the new 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
(lb-inch) torque wrench.
^ Rotational torque must be at least the recorded original torque plus a maximum of 5 lb-in.
9. Install the rear brake disc
10. Install the rear driveshaft.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential > Page 5395
Pinion Flange: Service and Repair Dana 30 Front Drive Axle/Differential
Drive Pinion Flange and Seal
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential > Page 5396
Removal
NOTE: This operation disturbs the pinion bearing preload. Carefully reset the pinion bearing
preload during assembly.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. NOTE: The front wheels and tires and brake calipers must be removed to prevent drag during
the pinion bearing preload recording and
adjustment.
Remove the front tires and wheels.
3. Remove the front driveshaft.
4. CAUTION: When removing the disc brake caliper, never allow it to hang from the brake hose or
damage to the component may occur.
Remove the 4 disc brake caliper anchor bolts, then remove the disc brake calipers and disc brake
caliper anchors as an assembly. ^
Using mechanic's wire, position and support the disc brake calipers and disc brake caliper anchors.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential > Page 5397
5. Measure and record the pinion bearing preload.
^ Using a Nm torque wrench, rotate the pinion gear. Measure the torque required to maintain pinion
gear rotation.
6. Index-mark the pinion flange and the pinion gear stem.
7. Using the special tool to hold the pinion flange, remove and discard the pinion nut.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential > Page 5398
8. Using the special tool, remove the pinion flange.
9. Inspect the pinion flange for burrs and damage. Inspect the end of the pinion flange that contacts
the pinion bearing cone, pinion nut counterbore
and drive pinion oil seal surface for nicks. Discard the pinion flange if damaged.
10. Using gripping pliers and a hammer, remove the drive pinion oil seal.
11. Remove the drive pinion oil slinger and the outer pinion bearing.
12. Remove and discard the collapsible spacer. 13. Verify the splines on the pinion stem are free of
burrs. If burrs are evident, remove them with a fine crocus cloth. 14. Clean the drive pinion oil seal
bore.
Installation
1. Install a new collapsible spacer. 2. Install the outer pinion bearing and the drive pinion oil slinger.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential > Page 5399
3. NOTE: Lubricate the drive pinion oil seal lips with axle lubricant.
Using the special tool, install the drive pinion oil seal.
4. CAUTION: Never install the pinion flange with power tools or damage to the component may
occur.
Align the index marks and using the special tool, install the pinion flange.
5. Install the new pinion nut. Only hand-tighten the pinion nut at this time.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential > Page 5400
6. CAUTION: Do not loosen the pinion nut to reduce pinion bearing preload. Install a new
collapsible spacer and pinion nut if pinion
bearing preload reduction is necessary or damage to the component may occur.
Using the special tool to hold the pinion flange, tighten the pinion nut to set the pinion bearing
preload. ^
Tighten the pinion nut, rotating the pinion occasionally to make sure the pinion bearings are seating
correctly. Take frequent pinion bearing preload readings by rotating the pinion gear with a Nm
torque wrench. The final reading must be 0.56 Nm (5 lb-inch) more than the initial reading taken
during removal.
7. Install the disc brake calipers and disc brake caliper anchors as an assembly, then the 4 disc
brake caliper anchor bolts.
^ Tighten to 108 Nm (80 lb-ft).
8. CAUTION: Always connect the front driveshaft to the axle first. Otherwise, the weight of the
driveshaft may pinch the boot between the
shaft and the flange and cause the boot to tear.
NOTE: Install the driveshaft with new bolts and washers and new bolts and U-joint retainers. If new
bolts are not available, coat the threads of the original bolts with Threadlock(R) and sealer.
Install the front driveshaft.
9. Install the front tires and wheels.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential
Drive Pinion Flange and Drive Pinion Seal
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5405
Removal
1. CAUTION: The color on the rear face of the drive pinion nut is critical to this repair. Use the
same color new drive pinion nut for
installation. If a new collapsible spacer must be installed for pinion bearing preload reduction, install
the nut supplied with the new spacer kit or damage to the component may occur.
With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the rear wheel brake disc.
3. Remove the rear driveshaft. 4. Install a Nm (lb-inch) torque wrench on the pinion nut and record
the torque necessary to maintain rotation of the drive pinion gear through several
revolutions.
CAUTION: The color on the rear face of the drive pinion nut is critical to this repair. Use the same
color new drive pinion nut for installation or damage to the component may occur.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5406
5. Using the special tool to hold the pinion flange, remove and discard the pinion nut.
6. Index-mark the pinion flange and drive pinion gear to maintain initial balance during installation.
7. Using the special tool, remove the pinion flange.
8. 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5407
Installation
1. If removed, lubricate the lips of the new drive pinion seal with grease.
2. NOTE: If the drive pinion seal becomes misaligned during installation, remove the drive pinion
seal and install a new drive pinion seal.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5408
7. CAUTION: The color on the rear face of the drive pinion nut is critical to this repair. Use the
same color new drive pinion nut for
installation or damage to the component may occur.
Select the new pinion nut for installation. Install and hand-tighten the pinion nut.
8.8 In. Pinion Nut
8. 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 or
component damage may occur. Install the new pinion nut that is included in the collapsible spacer
kit.
Tighten the new 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
(lb-inch) torque wrench.
^ Rotational torque must be at least the recorded original torque plus a maximum of 5 lb-in.
9. Install the rear brake disc
10. Install the rear driveshaft.
Dana 30 Front Drive Axle/Differential
Drive Pinion Flange and Seal
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5409
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5410
Removal
NOTE: This operation disturbs the pinion bearing preload. Carefully reset the pinion bearing
preload during assembly.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. NOTE: The front wheels and tires and brake calipers must be removed to prevent drag during
the pinion bearing preload recording and
adjustment.
Remove the front tires and wheels.
3. Remove the front driveshaft.
4. CAUTION: When removing the disc brake caliper, never allow it to hang from the brake hose or
damage to the component may occur.
Remove the 4 disc brake caliper anchor bolts, then remove the disc brake calipers and disc brake
caliper anchors as an assembly. ^
Using mechanic's wire, position and support the disc brake calipers and disc brake caliper anchors.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5411
5. Measure and record the pinion bearing preload.
^ Using a Nm torque wrench, rotate the pinion gear. Measure the torque required to maintain pinion
gear rotation.
6. Index-mark the pinion flange and the pinion gear stem.
7. Using the special tool to hold the pinion flange, remove and discard the pinion nut.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5412
8. Using the special tool, remove the pinion flange.
9. Inspect the pinion flange for burrs and damage. Inspect the end of the pinion flange that contacts
the pinion bearing cone, pinion nut counterbore
and drive pinion oil seal surface for nicks. Discard the pinion flange if damaged.
10. Using gripping pliers and a hammer, remove the drive pinion oil seal.
11. Remove the drive pinion oil slinger and the outer pinion bearing.
12. Remove and discard the collapsible spacer. 13. Verify the splines on the pinion stem are free of
burrs. If burrs are evident, remove them with a fine crocus cloth. 14. Clean the drive pinion oil seal
bore.
Installation
1. Install a new collapsible spacer. 2. Install the outer pinion bearing and the drive pinion oil slinger.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5413
3. NOTE: Lubricate the drive pinion oil seal lips with axle lubricant.
Using the special tool, install the drive pinion oil seal.
4. CAUTION: Never install the pinion flange with power tools or damage to the component may
occur.
Align the index marks and using the special tool, install the pinion flange.
5. Install the new pinion nut. Only hand-tighten the pinion nut at this time.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5414
6. CAUTION: Do not loosen the pinion nut to reduce pinion bearing preload. Install a new
collapsible spacer and pinion nut if pinion
bearing preload reduction is necessary or damage to the component may occur.
Using the special tool to hold the pinion flange, tighten the pinion nut to set the pinion bearing
preload. ^
Tighten the pinion nut, rotating the pinion occasionally to make sure the pinion bearings are seating
correctly. Take frequent pinion bearing preload readings by rotating the pinion gear with a Nm
torque wrench. The final reading must be 0.56 Nm (5 lb-inch) more than the initial reading taken
during removal.
7. Install the disc brake calipers and disc brake caliper anchors as an assembly, then the 4 disc
brake caliper anchor bolts.
^ Tighten to 108 Nm (80 lb-ft).
8. CAUTION: Always connect the front driveshaft to the axle first. Otherwise, the weight of the
driveshaft may pinch the boot between the
shaft and the flange and cause the boot to tear.
NOTE: Install the driveshaft with new bolts and washers and new bolts and U-joint retainers. If new
bolts are not available, coat the threads of the original bolts with Threadlock(R) and sealer.
Install the front driveshaft.
9. Install the front tires and wheels.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5415
Seals and Gaskets: Service and Repair Stub Shaft Pilot Bearing and Seal
Ford 8.8-Inch Ring Gear Rear Drive Axle/Differential
Stub Shaft Pilot Bearing and Seal
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5416
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.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5417
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.
6. Install the halfshaft assembly.
Dana 30 Front Drive Axle/Differential
Stub Shaft Pilot Bearing and Seal
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5418
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5419
Removal
Both sides
1. Remove the halfshafts.
Right side
2. Remove the axle shaft.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5420
Both sides
3. Using the special tool and a suitable slide hammer, remove the stub shaft oil seals.
4. Using the special tool and a slide hammer, remove the stub shaft pilot bearings.
5. Clean the bearing and seal surfaces of any foreign material.
Installation
Right side
1. Using the special tools, install the stub shaft pilot bearing.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5421
2. Using the special tools, install the stub shaft oil seals.
3. Install the axle shaft.
Left side
4. Using the special tools, install the stub shaft bearing.
5. Using the special tools, install the stub shaft seal.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5422
Both sides
6. Refill the front drive axle to the correct level with lubricant. 7. Install the halfshafts.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Torque Specifications
Torque Specifications
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Specifications > Mechanical Specifications > Page 5428
Axle Shaft Assembly: Capacity Specifications
Material
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Specifications > Mechanical Specifications > Page 5429
Axle Shaft Assembly: Fluid Type Specifications
Material
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Specifications > Page 5430
Axle Shaft Assembly: Description and Operation
Rear Drive Halfshafts
The rear drive halfshafts consist of the following: ^
Inner constant velocity (CV) joints
^ Outer CV joints
^ Interconnecting shafts
^ Convoluted CV joint boots
^ CV joint boot clamps
^ Special CV high-temperature grease
^ Tripod joint housings
^ Ball and cage housings
^ A circlip stopper that holds the cross-groove inboard race assembly (inboard CV joint) together
^ A circlip that retains the splined inboard CV joint to the differential side gear
^ The RH and LH halfshafts are different lengths, with the LH halfshaft being the longer of the 2.
The rear drive halfshafts link the rear axle to the rear wheel hubs. The CV joints allow the halfshafts
to rotate smoothly through the required changes in angles between the stationary axle and the
varying angles of the rear wheels including jounce and rebound. The CV joints are either tri-lobed
style or the caged ball type depending on inboard or outboard. New halfshaft components are
available as kits containing grease, boots and clamps.
Handle all halfshaft components carefully during removal and installation and during various
component disassembly and assembly procedures. Never pick up or hold the halfshaft only by the
inboard or outboard CV joint. 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 from the hub. 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 only by the interconnecting shaft to avoid
pull-apart and potential damage to the CV joints. Excessive pulling force on the interconnecting
shaft between joints of the halfshaft will result in internal joint damage. Axial loads used in assisting
removal must be applied through the inboard joint housing only. Do not drop assembled halfshafts.
The impact will cut the boots from the inside without evidence of external damage. Do not remove
the outer CV joint by pulling on the interconnecting shaft. Inspect all machined surfaces and splines
for damage.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Specifications > Page 5431
Axle Shaft Assembly: Testing and Inspection
Inspection and Verification
1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical damage.
Visual Inspection Chart
Visual Inspection Chart
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 and
GO to Symptom Chart - Driveline or GO to Symptom Chart - Noise, Vibration and
Harshness (NVH). See: Differential Assembly/Testing and Inspection/Symptom Related Diagnostic
Procedures/Symptom Chart - Driveline See: Differential Assembly/Testing and
Inspection/Symptom Related Diagnostic Procedures/Symptom Chart - Noise, Vibration and
Harshness (NVH)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 5434
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 5435
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.
2. Remove the rear wheel and tire. 3. Remove and discard the rear axle wheel end nut.
^ To install, tighten to 275 Nm (203 lb-ft).
4. 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.
Using the special tool, press the outboard constant velocity (CV) joint until it is loose in the hub.
5. Remove the brake cable retainer screw.
^ To install, tighten to 20 Nm (15 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 5436
6. Remove and discard the outboard toe link nut and back out the bolt for clearance.
^ To install, tighten to 350 Nm (259 lb-ft) at curb ride height.
7. Remove and discard the lower arm outboard bolt.
^ To install, tighten to 275 Nm (203 lb-ft) at curb ride height.
8. Remove and discard the 3 wheel knuckle bolts.
^ To install, tighten to 275 Nm (203 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 5437
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 lb-ft) at curb ride height.
10. 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.
NOTE: 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.
NOTE: Always install a new differential stub shaft seal whenever the halfshaft is removed.
NOTE: Make sure the halfshaft is completely seated in the differential side gear by pushing the
halfshaft into the rear axle assembly until an audible click is heard or a leak may occur from the
axle assembly.
NOTE: Apply the brake to keep the halfshaft from rotating.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 5438
13. Carry out a rear wheel alignment.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 5439
Axle Shaft Assembly: Overhaul
Halfshaft Joint
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 5440
Disassembly
1. Remove the halfshaft assembly. 2. For the inboard CV joint, carry out the following:
1 Remove and discard the boot clamps.
2 Remove the inboard CV joint housing.
3. For the inboard CV joint, carry out the following:
1 Remove and discard the retainer circlip.
2 Slide the boot away from the CV joint.
4. Using a suitable 3-jaw puller, remove the CV joint.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 5441
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, carry out the following: 1
Remove and discard the boot clamps.
2 Remove and discard the boot.
Assembly
1. For the outboard CV joint, carry out the following:
1 Slide the boot on the interconnecting shaft.
2 Pack the outboard CV joint with 225 g (7.93 oz) of grease.
3 Spread any remaining grease evenly inside the boot.
4 Install the boot by seating it in the groove in the CV joint housing.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 5442
2. Using the special tool, install the boot clamps.
3. NOTE: Install a new circlip every time the halfshaft is removed from the axle.
Install a new retainer circlip.
4. Remove and discard the inboard halfshaft excluder seal, if equipped.
5. For the inboard CV joint, carry out the following:
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 5443
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, carry out the following:
1 Pack the inboard CV joint housing with 250 g (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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 5444
9. Set the halfshaft assembled length to specifications.
1 Measure the entire assembly length.
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 5453
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 (V8-4.6L (2008))
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 5454
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 (V8-4.6L (2008))
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 5455
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 (V8-4.6L (2008))
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 5456
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 5461
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 5467
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 (V8-4.6L (2008))
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 5468
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 (V8-4.6L (2008))
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 5469
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 (V8-4.6L (2008))
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 5470
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 5475
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 (V8-4.6L (2008))
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
5476
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 (V8-4.6L (2008))
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
5477
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 (V8-4.6L (2008))
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
5478
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 (V8-4.6L (2008))
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
5479
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 (V8-4.6L (2008))
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
5480
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 (V8-4.6L (2008))
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
5481
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 (V8-4.6L (2008))
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
5482
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 (V8-4.6L (2008))
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
5483
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 (V8-4.6L (2008))
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
5484
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 (V8-4.6L (2008))
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
5485
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 (V8-4.6L (2008))
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
5486
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 (V8-4.6L (2008))
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
5487
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 (V8-4.6L (2008))
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
5488
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 (V8-4.6L (2008))
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
Wheel Bearing and Wheel Hub
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure may result in major service expense. New parts must be
installed with the same part numbers or equivalent part, if replacement is 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 and tire.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Service and Repair > Front > Page 5493
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 lb-ft).
3. Remove the brake disc.
4. NOTE: Inspect and if necessary, clean area around wheel speed sensor before removing it from
the wheel bearing and hub.
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 lb-ft).
5. Remove the 3 bolts and the wheel bearing and wheel hub.
^ Discard the bolts.
^ To install, tighten to 122 Nm (90 lb-ft).
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Service and Repair > Front > Page 5494
Wheel Bearing: Service and Repair Rear
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 may result in major service expense. New parts must be
installed with the same part numbers or equivalent part, if replacement is 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 lb-inch).
3. Using the special tool and a suitable press, remove the wheel hub.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Service and Repair > Front > Page 5495
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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut >
Component Information > Specifications > Rear Axle Wheel End Nut
Axle Nut: Specifications Rear Axle Wheel End Nut
Rear Axle Wheel End Nut ....................................................................................................................
................................................ 275 Nm (203 lb-ft).
Discard the wheel end nut.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut >
Component Information > Specifications > Rear Axle Wheel End Nut > Page 5501
Axle Nut: Specifications Rear Axle Halfshaft Nut
Rear Axle Halfshaft Nut .......................................................................................................................
................................................ 275 Nm (203 lb-ft).
Install a new halfshaft nut and washer.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
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 U-joint yoke ears in a vise so that the C-washer is pointing up and the front
section is free to move.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support >
Component Information > Service and Repair > Page 5506
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 lb-ft).
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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support >
Component Information > Service and Repair > Page 5507
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 (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Driveshaft - Front
Drive/Propeller Shaft: Service and Repair Driveshaft - Front
Driveshaft - Front
Driveshaft - Front
Removal and Installation
CAUTION: Always disconnect the front driveshaft from the transfer case first. Otherwise, the weight
of the driveshaft may pinch the boot between the driveshaft and damage the constant velocity (CV)
joint flange which may cause the boot to tear.
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Index-mark the front driveshaft to
maintain driveshaft balance.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5512
3. Remove and discard the 6 CV flange bolts and 3 CV joint washers.
^ To install, tighten the new bolts to 30 Nm (22 lb-ft).
4. Remove the 4 U-joint strap bolts and remove the 2 U-joint straps.
^ Discard the bolts.
^ To install, tighten the new bolts to 19 Nm (14 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5513
5. Remove the front driveshaft.
6. CAUTION: Tighten the constant velocity (CV) joint bolts evenly in a cross pattern or damage will
occur to the CV joint.
NOTE: The can (domed CV joint housing cover) is pressed into the CV joint housing at the factory.
When housed correctly, the can will appear as shown in the cut-away illustration (top box). Do not
reseat the can in the CV joint housing if the can's flange is above the CV joint housing as shown in
the cut-away illustration (bottom box), install a new driveshaft.
NOTE: The CV joint is not serviceable. Install a new driveshaft if damaged.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5514
Drive/Propeller Shaft: Service and Repair Driveshaft - Rear, One-Piece
Driveshaft - Rear, One-Piece, Rear Wheel Drive (RWD)
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5515
3. Index-mark the driveshaft flange to the pinion flange to maintain driveshaft balance.
4. Remove and discard the 4 driveshaft pinion flange bolts.
^ To install, tighten the new bolts to 112 Nm (83 lb-ft).
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 and remove the driveshaft from the extension housing.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5516
6. NOTE: 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.
NOTE: If new driveshaft flange bolts are not available, coat the threads of the original driveshaft
flange bolts with Threadlock(R) and sealer.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5517
Drive/Propeller Shaft: Service and Repair Driveshaft - Rear, Two-Piece
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. 2. Remove the 2 nuts from the driveshaft
center bearing bracket.
^ To install, tighten to 55 Nm (41 lb-ft).
3. Index-mark the rear U-joint flange to the differential pinion flange.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5518
4.0L engine
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 U-joint flange to the transmission output flange.
6. Remove and discard the 4 driveshaft flange bolts from the transmission output shaft flange.
^ To install, tighten the 4 new bolts to 112 Nm (83 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5519
All vehicles
7. Remove and discard the 4 driveshaft flange bolts from the drive pinion flange.
^ To install, tighten the 4 new bolts to 112 Nm (83 lb-ft).
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 and remove
the driveshaft.
10. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5520
Drive/Propeller Shaft: Service and Repair Driveshaft Slip Yoke Boot
Driveshaft Slip Yoke Boot
Removal
1. Remove the driveshaft. 2. Index mark the driveshaft on both sides of the driveshaft slip yoke
boot.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5521
3. Remove and discard the 2 driveshaft slip yoke boot clamps. 4. Separate the driveshaft. 5.
Remove the driveshaft slip yoke boot.
Installation
1. NOTE: Grease both ends of the driveshaft.
Position the driveshaft slip yoke boot and the 2 driveshaft slip yoke boot clamps on one end of the
driveshaft.
2. Align the index marks and connect the driveshaft.
3. Using the special tool, install the new driveshaft slip yoke boot.
4. Install the driveshaft.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications
Flex Plate: Specifications
Flexplate Bolts .....................................................................................................................................
...................................................... 80 Nm (59 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page
5525
Flex Plate: Testing and Inspection
Flexplate Inspection
1. Inspect the flexplate for:
1 Any cracks.
2 Worn ring gear teeth.
3 Chipped or cracked ring gear teeth.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page
5526
Flex Plate: Service and Repair
Flexplate
Flexplate or Flywheel and Crankshaft Rear Seal - Exploded View
Removal and Installation
1. Remove the transmission. 2. Remove the 6 bolts and the flexplate.
^ To install, tighten to 80 Nm (59 lb-ft) in the sequence shown.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page
5527
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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: > 09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle
Control Module: Customer Interest Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle
TSB 09-22-6
11/16/09
4.6L ENGINE -CHECK ENGINE LIGHT ON - DTC P0196 - COLD WEATHER DRIVING
CONDITIONS- CALIBRATION UPDATE
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
ISSUE Some 2006-2008 Explorer, Mountaineer and Sport Trac vehicles and equipped with 4.6L
3-V engines may exhibit:
^ Diagnostic trouble code (DTC) P0196 - engine oil temperature (EOT) sensor range/performance
during ice/snow driving conditions.
^ Idle speed dropping below specification, hesitation or loss of RPM with no DTCs stored in the
Powertrain Control Module (PCM).
^ Cruise control surge at approximately 50-60 MPH (80-97 Km/h) in hilly regions Only applies to
vehicles operated in altitudes above 5000 feet (1.52
km).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
If normal Powertrain Controls/Emissions Diagnosis (PC/ED) diagnostics do not resolve the above
vehicle concerns, reprogram the PCM and Transmission Control Module (1CM) to the latest
calibration using IDS release 63.08 and higher. This new calibration is not included in the VCM
2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
VEHICLES EQUIPPED WITH A PCM AND TCM, REQUIRE A COORDINATED
REPROGRAMMING.
THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS
OUTLINED BY THE INTERGRATED DIAGNOSTIC SYSTEM (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 63.08 and higher. This new calibration
is not included in the VCM 2009.9 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:
(1) Choose all Tests and Calibrations.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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: > 09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle > Page 5546
(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
DISCONNECTING 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 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. Brake gently to a complete
stop and hold foot on brake for at least 10 seconds.
g. Repeat Steps (e-f) a total of three (3) 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
092206A 2006-2008 Explorer, 1.0 Hr.
Mountaineer 2007-2008 Explorer Sport Trac: Check DTCs, Reprogram The PCM And TCM
Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor
Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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: > 09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle
Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0196/RPM
Loss/Slow Idle
TSB 09-22-6
11/16/09
4.6L ENGINE -CHECK ENGINE LIGHT ON - DTC P0196 - COLD WEATHER DRIVING
CONDITIONS- CALIBRATION UPDATE
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
ISSUE Some 2006-2008 Explorer, Mountaineer and Sport Trac vehicles and equipped with 4.6L
3-V engines may exhibit:
^ Diagnostic trouble code (DTC) P0196 - engine oil temperature (EOT) sensor range/performance
during ice/snow driving conditions.
^ Idle speed dropping below specification, hesitation or loss of RPM with no DTCs stored in the
Powertrain Control Module (PCM).
^ Cruise control surge at approximately 50-60 MPH (80-97 Km/h) in hilly regions Only applies to
vehicles operated in altitudes above 5000 feet (1.52
km).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
If normal Powertrain Controls/Emissions Diagnosis (PC/ED) diagnostics do not resolve the above
vehicle concerns, reprogram the PCM and Transmission Control Module (1CM) to the latest
calibration using IDS release 63.08 and higher. This new calibration is not included in the VCM
2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
VEHICLES EQUIPPED WITH A PCM AND TCM, REQUIRE A COORDINATED
REPROGRAMMING.
THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS
OUTLINED BY THE INTERGRATED DIAGNOSTIC SYSTEM (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 63.08 and higher. This new calibration
is not included in the VCM 2009.9 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:
(1) Choose all Tests and Calibrations.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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: > 09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle > Page
5552
(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
DISCONNECTING 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 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. Brake gently to a complete
stop and hold foot on brake for at least 10 seconds.
g. Repeat Steps (e-f) a total of three (3) 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
092206A 2006-2008 Explorer, 1.0 Hr.
Mountaineer 2007-2008 Explorer Sport Trac: Check DTCs, Reprogram The PCM And TCM
Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor
Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Page 5553
View 151-12
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Page 5554
C199
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams
C2260
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5565
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5566
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5567
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5568
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5569
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5570
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5571
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5572
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5573
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5574
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5575
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5576
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 5577
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Page 5578
Brake Switch - TCC: Description and Operation
BRAKE PEDAL POSITION (BPP) SWITCH
Typical BPP Switch
The BPP switch is sometimes referred to as the 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 antilock 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 (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5583
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5584
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5585
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5586
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5587
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5588
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5589
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5590
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5591
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5592
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5593
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5594
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 5595
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5600
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5601
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5602
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5603
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5604
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5605
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5606
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5607
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5608
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5609
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5610
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5611
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 5612
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations
View 151-15
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5618
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5619
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5620
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5621
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5622
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5623
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5624
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5625
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5626
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5627
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5628
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5629
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 5630
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 5633
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 (V8-4.6L (2008))
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 5634
Transmission Mode Switch: Service and Repair
Transmission Control (TC) Switch
Transmission Control (TC) Switch
Removal
1. Remove the selector lever knob. 2. Remove the transmission control (TC) switch from the knob.
Installation
1. Install the TC switch into the selector lever knob. 2. Install the selector lever knob.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Transmission Position Switch/Sensor: Locations
View 151-7
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Page 5638
View 151-11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5641
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5642
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5643
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5644
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5645
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5646
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5647
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5648
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5649
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5650
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5651
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5652
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 5653
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5654
C167
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5655
Transmission Position Switch/Sensor: Adjustments
Transmission Range (TR) Sensor Adjustment - 5R55S
Adjust
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever 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 digital transmission range (TR) sensor electrical
connector.
4. Disconnect the digital TR sensor electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5656
5. Remove the selector lever cable end from the manual control lever.
6. Remove the outer manual control lever nut and the 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 lb-inch).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5657
9. Install the outer manual lever and nut.
^ Tighten to 48 Nm (35 lb-ft).
10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable
bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable
to make sure that it is locked into the selector lever cable 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 selector lever cable end is correctly installed.
Install the selector lever cable end onto the manual control lever.
11. Reconnect the digital TR sensor electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5658
12. Move the rubber boot back over the TR electrical connector.
13. NOTE: If the selector lever cable shield is loose on the selector lever cable, replace the selector
lever cable shield.
Install the selector lever cable shield.
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 (V8-4.6L (2008))
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 5659
Transmission Position Switch/Sensor: Service and Repair
Digital Transmission Range (TR) Sensor - 5R55S
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by
prying on the side of the selector lever cable shield closest to the boot, then sliding the selector
lever
cable shield away from the boot.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5660
3. Move the rubber boot back to gain access to the digital transmission range (TR) sensor electrical
connector.
4. Disconnect the digital TR sensor electrical connector.
5. Remove the selector lever cable from the manual control lever.
6. Remove the outer manual control lever.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5661
7. Remove the digital TR sensor.
Installation
1. CAUTION: The digital transmission range (TR) 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. ^
Tighten to 8 Nm (71 lb-inch).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5662
3. Install the outer manual lever.
^ Tighten to 48 Nm (35 lb-ft).
4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen
for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that
it is locked into the selector lever cable 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
selector lever cable end is correctly installed.
Install the selector lever cable to the manual control lever.
5. Connect the digital TR sensor electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5663
6. Move the rubber boot back over the TR sensor electrical connector.
7. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector
lever cable shield.
Install the selector lever cable shield.
8. Verify that the selector lever cable is adjusted correctly.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 151-11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5668
Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor
View 151-7
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5669
View 151-11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5670
View 151-11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5673
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5674
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5675
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5676
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5677
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5678
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5679
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 terminal by pulling each wire at the end of the connector.
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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 5680
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
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and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5681
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
3 = Splice tape
4 = Harness tape
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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 5682
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5683
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.
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 6.35mm (1/4 in) 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.
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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 5684
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.
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, barrel squeeze tool handles appropriate 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.
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and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5685
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
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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 5686
Transmission Speed Sensor: Connector Views
C193
C143
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and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5687
C164
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft
Speed Sensor - 5R55S
Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor - 5R55S
Intermediate Shaft Speed Sensor
Intermediate Shaft Speed Sensor
Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
Four wheel drive (4WD) vehicles
2. Disconnect the front driveshaft from the transfer case.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft
Speed Sensor - 5R55S > Page 5690
3. Disconnect the front driveshaft from the front differential.
4. Remove the front driveshaft from the vehicle.
All vehicles
5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield
closest to the boot, then sliding the selector lever
cable shield away from the boot.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft
Speed Sensor - 5R55S > Page 5691
6. Remove the selector lever cable and selector lever cable 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.
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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 > Intermediate Shaft
Speed Sensor - 5R55S > Page 5692
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.
2 Tighten the intermediate shaft speed sensor screw.
^ Tighten to 14 Nm (10 lb-ft).
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 selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable
bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable
to make sure that it is locked into the selector lever cable 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 selector lever cable end is correctly installed.
Install the selector lever cable and selector lever cable bracket. ^
Tighten to 40 Nm (30 lb-ft).
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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 > Intermediate Shaft
Speed Sensor - 5R55S > Page 5693
4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector
lever cable shield.
Install the selector lever cable shield.
4WD vehicles
5. Install the front driveshaft in the vehicle.
6. Connect the front driveshaft to the transfer case.
^ Tighten to 30 Nm (22 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft
Speed Sensor - 5R55S > Page 5694
7. Connect the front driveshaft to the front differential.
^ Tighten to 19 Nm (14 lb-ft).
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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 > Intermediate Shaft
Speed Sensor - 5R55S > Page 5695
Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor - 5R55S
Output Shaft Speed (OSS) Sensor
Output Shaft Speed (OSS) Sensor
Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
Four wheel drive (4WD) vehicles
2. Disconnect the front driveshaft from the transfer case.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft
Speed Sensor - 5R55S > Page 5696
3. Disconnect the front driveshaft from the front differential.
4. Remove the front driveshaft from the vehicle.
All vehicles
5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield
closest to the boot, then sliding the selector lever
cable shield away from the boot.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft
Speed Sensor - 5R55S > Page 5697
6. Remove the selector lever cable and selector lever cable bracket.
7. Disconnect the heated oxygen sensor (HO2S) connector from the transmission case.
8. Disconnect the output shaft speed (OSS) sensor electrical connector.
9. Remove the OSS sensor.
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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 > Intermediate Shaft
Speed Sensor - 5R55S > Page 5698
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.
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 lb-ft).
2. Connect the OSS sensor electrical connector.
3. Connect the HO2S connector to the transmission case.
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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 > Intermediate Shaft
Speed Sensor - 5R55S > Page 5699
4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable
bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable
to make sure that it is locked into the selector lever cable 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 selector lever cable end is correctly installed.
Install the selector lever cable and selector lever cable bracket. ^
Tighten to 40 Nm (30 lb-ft).
5. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector
lever cable shield.
Install the selector lever cable shield.
4WD vehicles
6. Install the front driveshaft in the vehicle.
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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 > Intermediate Shaft
Speed Sensor - 5R55S > Page 5700
7. Connect the front driveshaft to the transfer case.
^ Tighten to 30 Nm (22 lb-ft).
8. Connect the front driveshaft to the front differential.
^ Tighten to 19 Nm (14 lb-ft).
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and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Intermediate Shaft
Speed Sensor - 5R55S > Page 5701
Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor - 5R55S
Turbine Shaft Speed (TSS) Sensor
Turbine Shaft Speed (TSS) Sensor
Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
Four wheel drive (4WD) vehicles
2. Disconnect the front driveshaft from the transfer case.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft
Speed Sensor - 5R55S > Page 5702
3. Disconnect the front driveshaft from the front differential.
4. Remove the front driveshaft from the vehicle.
All vehicles
5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield
closest to the boot, then sliding the selector lever
cable shield away from the boot.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft
Speed Sensor - 5R55S > Page 5703
6. Remove the selector lever cable and selector lever cable 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.
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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 > Intermediate Shaft
Speed Sensor - 5R55S > Page 5704
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.
2 Tighten the TSS sensor screw.
^ Tighten to 14 Nm (10 lb-ft).
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 selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable
bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable
to make sure that it is locked into the selector lever cable 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 selector lever cable end is correctly installed.
Install the selector lever cable and selector lever bracket. ^
Tighten to 40 Nm (30 lb-ft).
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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 > Intermediate Shaft
Speed Sensor - 5R55S > Page 5705
4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new shield.
Install the selector lever cable shield.
4WD vehicles
5. Install the front driveshaft in the vehicle.
6. Connect the front driveshaft to the transfer case.
^ Tighten to 30 Nm (22 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft
Speed Sensor - 5R55S > Page 5706
7. Connect the front driveshaft to the front differential.
^ Tighten to 19 Nm (14 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
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and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5711
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5712
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5713
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5714
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5715
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5716
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5717
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5718
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5719
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5720
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5721
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5722
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 5723
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component
Information > Diagrams
C2260
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control
Module, Transfer Case > Component Information > Diagrams
C2260
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > 5R55S - Automatic Transaxle/Transmission
Pressure Regulating Solenoid: Specifications 5R55S - Automatic Transaxle/Transmission
Solenoid Operation Chart
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > 5R55S - Automatic Transaxle/Transmission > Page 5739
Pressure Regulating Solenoid: Specifications 6R60 - Automatic Transaxle/Transmission
Solenoid Application Chart
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5742
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5743
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5744
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5745
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5746
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5747
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5748
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5749
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5750
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5751
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5752
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5753
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 5754
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5755
Pressure Regulating Solenoid: Testing and Inspection
Pinpoint Tests - OSC Equipped Vehicle
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 the following shift solenoid operation information when carrying out Pinpoint Test A.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5756
Solenoid Operation Chart (Part 1)
Solenoid Operation Chart (Part 2)
Shift Solenoid Failure Mode Chart
Failed ON or OFF due to PCM and/or vehicle wiring concerns, solenoid electrically, mechanically
or hydraulically stuck ON or OFF.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5757
SSA, SSB
SSC, SSD
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5758
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 (V8-4.6L (2008))
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 5759
Pressure Regulating Solenoid: Service and Repair
Solenoid Body Assembly
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5760
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid drain plug
and drain the transmission fluid.
3. NOTE: Clean the area around transmission control solenoid body harness connector to prevent
contamination of the transmission control solenoid
body harness connector.
Disconnect the transmission control solenoid body harness connector.
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
reused.
Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan
gasket.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Diagrams > Page 5761
5. Remove the transmission fluid pan filter.
6. CAUTION: Do not damage the solenoid body connector pins.
Remove the transmission control solenoid body screws and remove the transmission control
solenoid body by pulling down on the transmission control solenoid body and pushing down on the
transmission solenoid body connector from the other side of the case.
Installation
1. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the
O-ring seals with clean transmission fluid.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Diagrams > Page 5762
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 transmission control solenoid body. Tighten the transmission control solenoid body
screws in sequence shown. ^
Tighten to 8 Nm (71 lb-inch).
3. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with
clean transmission fluid.
NOTE: Make sure that the transmission fluid pan filter seals are correctly seated on the
transmission fluid pan filter.
Lubricate the transmission fluid pan seals and install the transmission fluid pan filter. ^
Tighten to 10 Nm (89 lb-inch).
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
reused.
Install the transmission fluid pan and transmission fluid pan gasket and loosely install the
transmission fluid pan screws.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5763
5. Tighten the transmission fluid pan screws in a crisscross sequence.
^ Tighten to 11 Nm (8 lb-ft).
6. CAUTION: Damage will occur to the transmission control solenoid body assembly if the screw is
tightened above the specification.
NOTE: Always install new O-ring seals on transmission control solenoid body harness connector.
NOTE: Clean the area around transmission control solenoid body harness connector to prevent
contamination of the transmission control solenoid body harness 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 control solenoid body harness connector
and connect the connector. ^
Tighten to 5 Nm (44 lb-inch).
7. Fill the transmission.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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.
2. Disconnect the brake shift interlock actuator electrical connector.
3. Remove the screw and the brake shift interlock actuator.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5767
Installation
1. Install the brake shift interlock actuator.
2. Connect the brake shift interlock actuator electrical connector.
3. Install the front floor console.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > 5R55S - Automatic Transaxle/Transmission
Shift Solenoid: Specifications 5R55S - Automatic Transaxle/Transmission
Solenoid Operation Chart
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > 5R55S - Automatic Transaxle/Transmission > Page 5772
Shift Solenoid: Specifications 6R60 - Automatic Transaxle/Transmission
Solenoid Application Chart
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
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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 5775
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
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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 5776
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5777
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
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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 5778
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5779
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5780
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5781
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5782
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5783
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5784
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.
3. lnstall 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 seat wire splice.
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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 5785
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5786
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 5787
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5788
Shift Solenoid: Testing and Inspection
Pinpoint Tests - OSC Equipped Vehicle
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 the following shift solenoid operation information when carrying out Pinpoint Test A.
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Page 5789
Solenoid Operation Chart (Part 1)
Solenoid Operation Chart (Part 2)
Shift Solenoid Failure Mode Chart
Failed ON or OFF due to PCM and/or vehicle wiring concerns, solenoid electrically, mechanically
or hydraulically stuck ON or OFF.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Page 5790
SSA, SSB
SSC, SSD
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5791
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 (V8-4.6L (2008))
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 5792
Shift Solenoid: Service and Repair
Solenoid Body Assembly
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Page 5793
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid drain plug
and drain the transmission fluid.
3. NOTE: Clean the area around transmission control solenoid body harness connector to prevent
contamination of the transmission control solenoid
body harness connector.
Disconnect the transmission control solenoid body harness connector.
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
reused.
Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan
gasket.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Page 5794
5. Remove the transmission fluid pan filter.
6. CAUTION: Do not damage the solenoid body connector pins.
Remove the transmission control solenoid body screws and remove the transmission control
solenoid body by pulling down on the transmission control solenoid body and pushing down on the
transmission solenoid body connector from the other side of the case.
Installation
1. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the
O-ring seals with clean transmission fluid.
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Page 5795
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 transmission control solenoid body. Tighten the transmission control solenoid body
screws in sequence shown. ^
Tighten to 8 Nm (71 lb-inch).
3. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with
clean transmission fluid.
NOTE: Make sure that the transmission fluid pan filter seals are correctly seated on the
transmission fluid pan filter.
Lubricate the transmission fluid pan seals and install the transmission fluid pan filter. ^
Tighten to 10 Nm (89 lb-inch).
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
reused.
Install the transmission fluid pan and transmission fluid pan gasket and loosely install the
transmission fluid pan screws.
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Page 5796
5. Tighten the transmission fluid pan screws in a crisscross sequence.
^ Tighten to 11 Nm (8 lb-ft).
6. CAUTION: Damage will occur to the transmission control solenoid body assembly if the screw is
tightened above the specification.
NOTE: Always install new O-ring seals on transmission control solenoid body harness connector.
NOTE: Clean the area around transmission control solenoid body harness connector to prevent
contamination of the transmission control solenoid body harness 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 control solenoid body harness connector
and connect the connector. ^
Tighten to 5 Nm (44 lb-inch).
7. Fill the transmission.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Application Chart
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
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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 5802
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 5803
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
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Information > Diagrams > Diagram Information and Instructions > Page 5804
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
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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 5805
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5806
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5807
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5808
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 terminal by pulling each wire at the end of the connector.
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Information > Diagrams > Diagram Information and Instructions > Page 5809
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
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Information > Diagrams > Diagram Information and Instructions > Page 5810
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
3 = Splice tape
4 = Harness tape
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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 5811
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.
3. lnstall 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 seat wire splice.
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Information > Diagrams > Diagram Information and Instructions > Page 5812
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.
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 6.35mm (1/4 in) 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.
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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 5813
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.
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, barrel squeeze tool handles appropriate 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.
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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 5814
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
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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 5815
Torque Converter Clutch Solenoid: Service and Repair
Solenoid Body Assembly
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Information > Diagrams > Page 5816
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid drain plug
and drain the transmission fluid.
3. NOTE: Clean the area around transmission control solenoid body harness connector to prevent
contamination of the transmission control solenoid
body harness connector.
Disconnect the transmission control solenoid body harness connector.
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
reused.
Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan
gasket.
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Information > Diagrams > Page 5817
5. Remove the transmission fluid pan filter.
6. CAUTION: Do not damage the solenoid body connector pins.
Remove the transmission control solenoid body screws and remove the transmission control
solenoid body by pulling down on the transmission control solenoid body and pushing down on the
transmission solenoid body connector from the other side of the case.
Installation
1. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the
O-ring seals with clean transmission fluid.
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Information > Diagrams > Page 5818
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 transmission control solenoid body. Tighten the transmission control solenoid body
screws in sequence shown. ^
Tighten to 8 Nm (71 lb-inch).
3. CAUTION: Damage may occur to transmission fluid filter seals if they are not lubricated with
clean transmission fluid.
NOTE: Make sure that the transmission fluid pan filter seals are correctly seated on the
transmission fluid pan filter.
Lubricate the transmission fluid pan seals and install the transmission fluid pan filter. ^
Tighten to 10 Nm (89 lb-inch).
4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not
damaged, the transmission fluid pan gasket should be
reused.
Install the transmission fluid pan and transmission fluid pan gasket and loosely install the
transmission fluid pan screws.
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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 5819
5. Tighten the transmission fluid pan screws in a crisscross sequence.
^ Tighten to 11 Nm (8 lb-ft).
6. CAUTION: Damage will occur to the transmission control solenoid body assembly if the screw is
tightened above the specification.
NOTE: Always install new O-ring seals on transmission control solenoid body harness connector.
NOTE: Clean the area around transmission control solenoid body harness connector to prevent
contamination of the transmission control solenoid body harness 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 control solenoid body harness connector
and connect the connector. ^
Tighten to 5 Nm (44 lb-inch).
7. Fill the transmission.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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: > 09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC
P0196/RPM Loss/Slow Idle
Control Module: Customer Interest Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle
TSB 09-22-6
11/16/09
4.6L ENGINE -CHECK ENGINE LIGHT ON - DTC P0196 - COLD WEATHER DRIVING
CONDITIONS- CALIBRATION UPDATE
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
ISSUE Some 2006-2008 Explorer, Mountaineer and Sport Trac vehicles and equipped with 4.6L
3-V engines may exhibit:
^ Diagnostic trouble code (DTC) P0196 - engine oil temperature (EOT) sensor range/performance
during ice/snow driving conditions.
^ Idle speed dropping below specification, hesitation or loss of RPM with no DTCs stored in the
Powertrain Control Module (PCM).
^ Cruise control surge at approximately 50-60 MPH (80-97 Km/h) in hilly regions Only applies to
vehicles operated in altitudes above 5000 feet (1.52
km).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
If normal Powertrain Controls/Emissions Diagnosis (PC/ED) diagnostics do not resolve the above
vehicle concerns, reprogram the PCM and Transmission Control Module (1CM) to the latest
calibration using IDS release 63.08 and higher. This new calibration is not included in the VCM
2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
VEHICLES EQUIPPED WITH A PCM AND TCM, REQUIRE A COORDINATED
REPROGRAMMING.
THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS
OUTLINED BY THE INTERGRATED DIAGNOSTIC SYSTEM (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 63.08 and higher. This new calibration
is not included in the VCM 2009.9 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:
(1) Choose all Tests and Calibrations.
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Service Bulletins > Customer Interest for Control Module: > 09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC
P0196/RPM Loss/Slow Idle > Page 5835
(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
DISCONNECTING 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 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. Brake gently to a complete
stop and hold foot on brake for at least 10 seconds.
g. Repeat Steps (e-f) a total of three (3) 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
092206A 2006-2008 Explorer, 1.0 Hr.
Mountaineer 2007-2008 Explorer Sport Trac: Check DTCs, Reprogram The PCM And TCM
Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor
Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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: > 09-22-6 > Nov > 09 > Engine Controls - MIL
ON/DTC P0196/RPM Loss/Slow Idle
Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0196/RPM
Loss/Slow Idle
TSB 09-22-6
11/16/09
4.6L ENGINE -CHECK ENGINE LIGHT ON - DTC P0196 - COLD WEATHER DRIVING
CONDITIONS- CALIBRATION UPDATE
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
ISSUE Some 2006-2008 Explorer, Mountaineer and Sport Trac vehicles and equipped with 4.6L
3-V engines may exhibit:
^ Diagnostic trouble code (DTC) P0196 - engine oil temperature (EOT) sensor range/performance
during ice/snow driving conditions.
^ Idle speed dropping below specification, hesitation or loss of RPM with no DTCs stored in the
Powertrain Control Module (PCM).
^ Cruise control surge at approximately 50-60 MPH (80-97 Km/h) in hilly regions Only applies to
vehicles operated in altitudes above 5000 feet (1.52
km).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
If normal Powertrain Controls/Emissions Diagnosis (PC/ED) diagnostics do not resolve the above
vehicle concerns, reprogram the PCM and Transmission Control Module (1CM) to the latest
calibration using IDS release 63.08 and higher. This new calibration is not included in the VCM
2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
VEHICLES EQUIPPED WITH A PCM AND TCM, REQUIRE A COORDINATED
REPROGRAMMING.
THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS
OUTLINED BY THE INTERGRATED DIAGNOSTIC SYSTEM (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 63.08 and higher. This new calibration
is not included in the VCM 2009.9 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:
(1) Choose all Tests and Calibrations.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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: > 09-22-6 > Nov > 09 > Engine Controls - MIL
ON/DTC P0196/RPM Loss/Slow Idle > Page 5841
(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
DISCONNECTING 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 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. Brake gently to a complete
stop and hold foot on brake for at least 10 seconds.
g. Repeat Steps (e-f) a total of three (3) 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
092206A 2006-2008 Explorer, 1.0 Hr.
Mountaineer 2007-2008 Explorer Sport Trac: Check DTCs, Reprogram The PCM And TCM
Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor
Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Page 5842
View 151-12
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Page 5843
C199
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Diagrams
C2260
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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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5854
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5855
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5856
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5857
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5858
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5859
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5860
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5861
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5862
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5863
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5864
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5865
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 5866
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5867
Brake Switch - TCC: Description and Operation
BRAKE PEDAL POSITION (BPP) SWITCH
Typical BPP Switch
The BPP switch is sometimes referred to as the 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 antilock 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 (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5872
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5873
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5874
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5875
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5876
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5877
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5878
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5879
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5880
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5881
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5882
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5883
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 5884
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5889
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5890
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5891
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5892
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5893
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5894
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5895
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5896
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5897
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5898
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5899
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5900
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 5901
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 >
Locations
View 151-15
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5907
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5908
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5909
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5910
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5911
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5912
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5913
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5914
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5915
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5916
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5917
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5918
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 5919
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 5922
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 (V8-4.6L (2008))
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 5923
Transmission Mode Switch: Service and Repair
Transmission Control (TC) Switch
Transmission Control (TC) Switch
Removal
1. Remove the selector lever knob. 2. Remove the transmission control (TC) switch from the knob.
Installation
1. Install the TC switch into the selector lever knob. 2. Install the selector lever knob.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Transmission Position Switch/Sensor: Locations
View 151-7
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Page 5927
View 151-11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
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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 5930
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5931
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5932
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5933
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5934
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5935
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5936
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 terminal by pulling each wire at the end of the connector.
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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 5937
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5938
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5939
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5940
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5941
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 5942
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5943
C167
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5944
Transmission Position Switch/Sensor: Adjustments
Transmission Range (TR) Sensor Adjustment - 5R55S
Adjust
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever 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 digital transmission range (TR) sensor electrical
connector.
4. Disconnect the digital TR sensor electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5945
5. Remove the selector lever cable end from the manual control lever.
6. Remove the outer manual control lever nut and the 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 lb-inch).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5946
9. Install the outer manual lever and nut.
^ Tighten to 48 Nm (35 lb-ft).
10. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable
bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable
to make sure that it is locked into the selector lever cable 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 selector lever cable end is correctly installed.
Install the selector lever cable end onto the manual control lever.
11. Reconnect the digital TR sensor electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5947
12. Move the rubber boot back over the TR electrical connector.
13. NOTE: If the selector lever cable shield is loose on the selector lever cable, replace the selector
lever cable shield.
Install the selector lever cable shield.
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 (V8-4.6L (2008))
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 5948
Transmission Position Switch/Sensor: Service and Repair
Digital Transmission Range (TR) Sensor - 5R55S
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by
prying on the side of the selector lever cable shield closest to the boot, then sliding the selector
lever
cable shield away from the boot.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5949
3. Move the rubber boot back to gain access to the digital transmission range (TR) sensor electrical
connector.
4. Disconnect the digital TR sensor electrical connector.
5. Remove the selector lever cable from the manual control lever.
6. Remove the outer manual control lever.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5950
7. Remove the digital TR sensor.
Installation
1. CAUTION: The digital transmission range (TR) 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. ^
Tighten to 8 Nm (71 lb-inch).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5951
3. Install the outer manual lever.
^ Tighten to 48 Nm (35 lb-ft).
4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen
for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that
it is locked into the selector lever cable 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
selector lever cable end is correctly installed.
Install the selector lever cable to the manual control lever.
5. Connect the digital TR sensor electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5952
6. Move the rubber boot back over the TR sensor electrical connector.
7. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector
lever cable shield.
Install the selector lever cable shield.
8. Verify that the selector lever cable is adjusted correctly.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 151-11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5957
Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor
View 151-7
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5958
View 151-11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5959
View 151-11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5962
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5963
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5964
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5965
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5966
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5967
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5968
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5969
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5970
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5971
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5972
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5973
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 5974
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5975
Transmission Speed Sensor: Connector Views
C193
C143
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 5976
C164
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S
Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor - 5R55S
Intermediate Shaft Speed Sensor
Intermediate Shaft Speed Sensor
Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
Four wheel drive (4WD) vehicles
2. Disconnect the front driveshaft from the transfer case.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S > Page 5979
3. Disconnect the front driveshaft from the front differential.
4. Remove the front driveshaft from the vehicle.
All vehicles
5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield
closest to the boot, then sliding the selector lever
cable shield away from the boot.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S > Page 5980
6. Remove the selector lever cable and selector lever cable 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S > Page 5981
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.
2 Tighten the intermediate shaft speed sensor screw.
^ Tighten to 14 Nm (10 lb-ft).
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 selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable
bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable
to make sure that it is locked into the selector lever cable 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 selector lever cable end is correctly installed.
Install the selector lever cable and selector lever cable bracket. ^
Tighten to 40 Nm (30 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S > Page 5982
4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector
lever cable shield.
Install the selector lever cable shield.
4WD vehicles
5. Install the front driveshaft in the vehicle.
6. Connect the front driveshaft to the transfer case.
^ Tighten to 30 Nm (22 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S > Page 5983
7. Connect the front driveshaft to the front differential.
^ Tighten to 19 Nm (14 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S > Page 5984
Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor - 5R55S
Output Shaft Speed (OSS) Sensor
Output Shaft Speed (OSS) Sensor
Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
Four wheel drive (4WD) vehicles
2. Disconnect the front driveshaft from the transfer case.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S > Page 5985
3. Disconnect the front driveshaft from the front differential.
4. Remove the front driveshaft from the vehicle.
All vehicles
5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield
closest to the boot, then sliding the selector lever
cable shield away from the boot.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S > Page 5986
6. Remove the selector lever cable and selector lever cable bracket.
7. Disconnect the heated oxygen sensor (HO2S) connector from the transmission case.
8. Disconnect the output shaft speed (OSS) sensor electrical connector.
9. Remove the OSS sensor.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S > Page 5987
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.
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 lb-ft).
2. Connect the OSS sensor electrical connector.
3. Connect the HO2S connector to the transmission case.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S > Page 5988
4. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable
bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable
to make sure that it is locked into the selector lever cable 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 selector lever cable end is correctly installed.
Install the selector lever cable and selector lever cable bracket. ^
Tighten to 40 Nm (30 lb-ft).
5. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector
lever cable shield.
Install the selector lever cable shield.
4WD vehicles
6. Install the front driveshaft in the vehicle.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S > Page 5989
7. Connect the front driveshaft to the transfer case.
^ Tighten to 30 Nm (22 lb-ft).
8. Connect the front driveshaft to the front differential.
^ Tighten to 19 Nm (14 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S > Page 5990
Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor - 5R55S
Turbine Shaft Speed (TSS) Sensor
Turbine Shaft Speed (TSS) Sensor
Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
Four wheel drive (4WD) vehicles
2. Disconnect the front driveshaft from the transfer case.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S > Page 5991
3. Disconnect the front driveshaft from the front differential.
4. Remove the front driveshaft from the vehicle.
All vehicles
5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield
closest to the boot, then sliding the selector lever
cable shield away from the boot.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S > Page 5992
6. Remove the selector lever cable and selector lever cable 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S > Page 5993
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.
2 Tighten the TSS sensor screw.
^ Tighten to 14 Nm (10 lb-ft).
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 selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable
bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable
to make sure that it is locked into the selector lever cable 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 selector lever cable end is correctly installed.
Install the selector lever cable and selector lever bracket. ^
Tighten to 40 Nm (30 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S > Page 5994
4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new shield.
Install the selector lever cable shield.
4WD vehicles
5. Install the front driveshaft in the vehicle.
6. Connect the front driveshaft to the transfer case.
^ Tighten to 30 Nm (22 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Intermediate Shaft Speed Sensor - 5R55S > Page 5995
7. Connect the front driveshaft to the front differential.
^ Tighten to 19 Nm (14 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
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Information > Diagrams > Diagram Information and Instructions > Page 6000
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
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Information > Diagrams > Diagram Information and Instructions > Page 6001
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
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Information > Diagrams > Diagram Information and Instructions > Page 6002
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
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Information > Diagrams > Diagram Information and Instructions > Page 6003
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Diagrams > Diagram Information and Instructions > Page 6004
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6005
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6006
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6007
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6008
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6009
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6010
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6011
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
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 6012
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Sensor Block >
Component Information > Locations
View 151-17
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Sensor Block >
Component Information > Locations > Page 6018
C3073
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Sensor Block >
Component Information > Locations > Page 6019
ABS Sensor Block: Service and Repair
Stability Control Sensor Cluster
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Sensor Block >
Component Information > Locations > Page 6020
Removal and Installation
NOTE: When installing a new stability control sensor cluster, the ABS module must be calibrated.
Follow the scan tool directions for the calibration procedures.
1. Remove the pin-type retainer and the LH floor console finish panel. 2. Remove the 2 bolts, 2
nuts and the LH instrument panel brace.
^ To install, tighten to 9 Nm (80 lb-in).
3. Remove the 2 bolts and LH floor 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 lb-in).
7. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic
Connector - ABS > Component Information > Diagrams
C126
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Locations
Electronic Brake Control Module: Locations
View 151-2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Locations > Page 6027
View 151-5
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Locations > Page 6028
Electronic Brake Control Module: Diagrams
C155 (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Locations > Page 6029
C155 (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Locations > Page 6030
Electronic Brake Control Module: Service and Repair
Anti-Lock Brake System (ABS) Module
Removal and Installation
CAUTION: Electronic modules are sensitive to electrical charges. The anti-lock brake system
(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 Programmable Module Installation in Information Bus (Module Configuration).
1. Remove the hydraulic control unit (HCU). 2. Remove the 4 screws and the ABS module.
^ To install, tighten to 2 Nm (18 lb-in).
3. CAUTION: Make sure that the anti-lock brake system (ABS) module is properly seated to the
hydraulic control unit (HCU) and that the
torque of the ABS module screws is correct, or damage to the components can occur.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Assembly,
Traction Control > Component Information > Service and Repair
Hydraulic Assembly: Service and Repair
Hydraulic Control Unit (HCU)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Assembly,
Traction Control > Component Information > Service and Repair > Page 6034
Removal and Installation
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification.
Additionally, do not use brake fluid that has been previously drained. Following these instructions
will help prevent system contamination, brake component damage and the risk of serious 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 serious 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 battery tray. 3. Disconnect the ABS module
electrical connector.
4. NOTE: The brake tubes must be installed in the same location as removed.
Remove the 2 master cylinder primary and secondary brake tube-to-hydraulic control unit (HCU)
fittings and position both brake tubes aside. ^
To install, tighten to 23 Nm (17 lb-ft).
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 lb-ft).
6. Remove the 3 HCU bracket-to-frame nuts.
^ To install, tighten to 23 Nm (17 lb-ft).
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Assembly,
Traction Control > Component Information > Service and Repair > Page 6035
^ To install, tighten to 18 Nm (13 lb-ft).
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 lb-in).
10. Remove the HCU bracket-to-HCU bolt and the HCU bracket.
^ To install, tighten to 9 Nm (80 lb-in).
11. To install, reverse the removal procedure.
^ Bleed the brake system.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral
Accelerometer > Component Information > Service and Repair > Page 6039
Removal and Installation
NOTE: When installing a new stability control sensor cluster, the ABS module must be calibrated.
Follow the scan tool directions for the calibration procedures.
1. Remove the pin-type retainer and the LH floor console finish panel. 2. Remove the 2 bolts, 2
nuts and the LH instrument panel brace.
^ To install, tighten to 9 Nm (80 lb-in).
3. Remove the 2 bolts and LH floor 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 lb-in).
7. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
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 (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control
Switch > Component Information > Locations
View 151-13
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control
Switch > Component Information > Locations > Page 6046
C280
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control
Switch > Component Information > Locations > Page 6047
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 lb-in).
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control
Switch > Component Information > Locations > Page 6048
5. Disconnect the stability traction control switch electrical connector and remove the stability
traction control switch from the instrument panel
center finish panel.
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front
Wheel Speed Sensor: Locations Wheel Speed Sensor, Left Front
View 151-2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 6053
View 151-5
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 6054
Wheel Speed Sensor: Locations Wheel Speed Sensor, Right Front
View 151-2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 6055
View 151-5
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 6056
Wheel Speed Sensor: Locations Wheel Speed Sensor, Left Rear
View 151-22
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 6057
View 151-27
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 6058
Wheel Speed Sensor: Locations Wheel Speed Sensor, Right Rear
View 151-24
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 6059
View 151-27
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front
C150
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 6062
C160
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 6063
C440
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 6064
C426
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
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. 4. Remove the wheel speed sensor harness
pin-type retainers. 5. Remove the wheel speed sensor bolt.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6067
^ To install, tighten to 17 Nm (13 lb-ft).
6. Remove the wheel speed sensor and the harness. 7. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6068
Wheel Speed Sensor: Service and Repair 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 lb-in).
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor >
Component Information > Service and Repair
Yaw Rate Sensor: Service and Repair
Stability Control Sensor Cluster
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor >
Component Information > Service and Repair > Page 6072
Removal and Installation
NOTE: When installing a new stability control sensor cluster, the ABS module must be calibrated.
Follow the scan tool directions for the calibration procedures.
1. Remove the pin-type retainer and the LH floor console finish panel. 2. Remove the 2 bolts, 2
nuts and the LH instrument panel brace.
^ To install, tighten to 9 Nm (80 lb-in).
3. Remove the 2 bolts and LH floor 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 lb-in).
7. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 6081
13480A, 9818A8)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2455 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 6087
13480A, 9818A8)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2455 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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
6093
13480A, 9818A8)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2455 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
ABS Hydraulic Control Unit (HCU) Bleeding
Brake Bleeding: Service and Repair ABS Hydraulic Control Unit (HCU) Bleeding
ABS Hydraulic Control Unit (HCU) Bleeding
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification.
Additionally, do not use brake fluid that has been previously drained. Following these instructions
will help prevent system contamination, brake component damage and the risk of serious 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 serious personal injury.
WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master
cylinder may be damaged if operated without fluid, resulting in degraded braking performance.
Failure to follow this instruction may result in serious 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.
NOTE: This procedure is only required when a new hydraulic control unit (HCU) is installed.
NOTE: When any part of the hydraulic system is disconnected for repair or installation of new
components, air can get into the system and cause spongy brake pedal action. This requires
bleeding of the hydraulic system after it is correctly connected. The hydraulic system can be bled
manually or with pressure bleeding equipment.
1. NOTE: Carrying out the System Bleed function drives trapped air from the HCU. Subsequent
bleeding removes the air from the brake hydraulic
system through the bleeder screws.
NOTE: Adequate voltage to the HCU module is required during the anti-lock control portion of the
system bleed.
Connect the scan tool to the vehicle.
2. Access the ABS HCU bleed function and follow the directions on the scan tool. 3. Manually
bleed the brake hydraulic system. 4. Repeat the procedure carrying out a total of 2 scan tool cycles
and 2 manual bleed cycles.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
ABS Hydraulic Control Unit (HCU) Bleeding > Page 6096
Brake Bleeding: Service and Repair Component Bleeding
Component Bleeding
Master Cylinder
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification.
Additionally, do not use brake fluid that has been previously drained. Following these instructions
will help prevent system contamination, brake component damage and the risk of serious 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 serious personal injury.
WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master
cylinder may be damaged if operated without fluid, resulting in degraded braking performance.
Failure to follow this instruction may result in serious personal injury.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If spilled, wipe up immediately
before damage to the painted or plastic surface occurs.
NOTE: When any part of the hydraulic system has been disconnected for repair or installation of
new components, air can enter the system and cause spongy brake pedal action. This requires
bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can
be bled manually or with pressure bleeding equipment.
NOTE: When 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 entering the system.
1. Disconnect the brake tubes from the master cylinder.
2. Install 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 (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
ABS Hydraulic Control Unit (HCU) Bleeding > Page 6097
3. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes, without air
bubbles. 4. Remove the short brake tubes and install the brake outlet tubes. 5. Bleed each brake
tube at the brake master cylinder as follows:
1 Have an assistant pump the brake pedal at least 2 times and then hold firm pressure on the
brake pedal.
2 Loosen the rearmost brake tube fitting until a stream of brake fluid comes out. While the assistant
maintains pressure on the brake pedal, tighten 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.
5 Tighten the master cylinder brake tube fittings to 18 Nm (13 lb-ft).
6. Bleed the brake system.
Brake Caliper
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification.
Additionally, do not use brake fluid that has been previously drained. Following these instructions
will help prevent system contamination, brake component damage and the risk of serious 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 serious personal injury.
WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master
cylinder may be damaged if operated without fluid, resulting in degraded braking performance.
Failure to follow this instruction may result in serious personal injury.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If spilled, wipe up immediately
before damage to the painted or plastic surface occurs.
NOTE: It is not necessary to do a complete brake system bleed if only the brake caliper was
disconnected or installed new.
1. Remove the brake caliper bleeder screw cap and place a box-end wrench on the bleeder screw.
Attach a rubber drain hose to the bleeder screw and
submerge the free end of the hose 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.
Loosen the bleeder screw until a stream of brake fluid comes out. While the assistant maintains
pressure on the brake pedal, tighten the bleeder
screw. ^
Repeat until clear, bubble-free fluid comes out.
^ Refill the brake master cylinder reservoir as necessary.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
ABS Hydraulic Control Unit (HCU) Bleeding > Page 6098
4. Tighten the brake caliper bleeder screw, remove the rubber hose and install the bleeder screw
cap.
^ Tighten the front brake caliper bleeder screw to 10 Nm (89 lb-in).
^ Tighten the rear brake caliper bleeder screw to 22 Nm (16 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
ABS Hydraulic Control Unit (HCU) Bleeding > Page 6099
Brake Bleeding: Service and Repair Brake System Bleeding
Brake System Bleeding
Pressure Bleed
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification.
Additionally, do not use brake fluid that has been previously drained. Following these instructions
will help prevent system contamination, brake component damage and the risk of serious 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 serious personal injury.
WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master
cylinder may be damaged if operated without fluid, resulting in degraded braking performance.
Failure to follow this instruction may result in serious 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.
NOTE: When any part of the hydraulic system has been disconnected for repair or installation of
new components, air can get into the system and cause spongy brake pedal action. This requires
bleeding of the hydraulic system after it has been correctly connected.
NOTE: Pressure bleed the brake system at 207-345 kPa (30-50 psi).
1. NOTE: If the hydraulic control unit (HCU) or any component upstream of the HCU are installed
new, carry out the Brake System Pressure
Bleeding procedure, then the anti-lock HCU bleed procedure, followed by another Brake System
Bleed Procedure.
Clean all the dirt from around the brake fluid reservoir cap and remove the cap. Fill the brake
master cylinder reservoir with clean, specified brake fluid.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
ABS Hydraulic Control Unit (HCU) Bleeding > Page 6100
2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers
of pressure bleeding equipment. Follow the
instructions of the manufacturer when installing the adapter.
Install the bleeder adapter to the brake master cylinder reservoir and attach the bleeder tank hose
to the fitting on the adapter.
3. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake
fluid to complete the bleeding operation.
Remove the RH rear brake caliper bleeder cap and place a box-end wrench on the bleeder screw.
Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a
container partially filled with clean, specified brake fluid.
4. Open the valve on the bleeder tank. 5. Loosen the RH rear brake caliper bleeder screw. Leave
open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw.
^ Press and release the parking brake 5 times.
^ Repeat until clear, bubble-free fluid comes out.
6. Tighten the RH rear brake caliper bleeder screw to 22 Nm (16 lb-ft), remove the rubber hose and
install the bleeder screw cap. 7. Repeat Steps 5 and 6 for the LH rear brake caliper.
^ Tighten the LH rear brake caliper bleeder screw to 22 Nm (16 lb-ft).
8. Continue bleeding the front of the system, going in order from the RH front brake caliper and
then to the LH front brake caliper.
^ Tighten the front brake caliper bleeder screws to 10 Nm (89 lb-in).
9. Close the bleeder tank valve. Remove the tank hose from the adapter and remove the adapter.
Fill the reservoir with clean, specified brake fluid
and install the reservoir cap.
Manual Bleeding
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification.
Additionally, do not use brake fluid that has been previously drained. Following these instructions
will help prevent system contamination, brake component damage and the risk of serious 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 serious personal injury.
WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master
cylinder may be damaged if operated without fluid, resulting in degraded braking performance.
Failure to follow this instruction may result in serious 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.
NOTE: When any part of the hydraulic system is disconnected for repair or installation of new
components, air can get into the system and cause spongy brake pedal action. This requires
bleeding of the hydraulic system after it is correctly connected. The hydraulic system can be bled
manually or with pressure bleeding equipment.
1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master
cylinder reservoir with clean, specified brake fluid.
2. NOTE: Bleed the brake system from the longest to the shortest brake line.
Remove the RH rear brake caliper bleeder screw cap and place a box-end wrench on the bleeder
screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a
container partially filled with clean, specified brake fluid.
3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 4.
Loosen the RH rear brake caliper bleeder screw until a stream of brake fluid comes out. While the
assistant maintains pressure on the brake pedal,
tighten the bleeder screw.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
ABS Hydraulic Control Unit (HCU) Bleeding > Page 6101
^ Repeat until clear, bubble-free fluid comes out.
^ Refill the brake master cylinder reservoir as necessary.
5. Tighten the RH rear brake caliper bleeder screw to 22 Nm (16 lb-ft), remove the rubber hose and
install the bleeder screw cap. 6. Repeat Steps 2 through 5 for the LH rear brake caliper bleeder
screw.
^ Tighten the LH rear brake caliper bleeder screw to 22 Nm (16 lb-ft).
7. Remove the RH front brake caliper bleeder screw cap and place a box-end wrench on the
bleeder screw. Attach a rubber drain hose to the bleeder
screw and submerge the free end of the hose in a container partially filled with clean, specified
brake fluid.
8. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 9.
Loosen the RH front brake caliper bleeder screw until a stream of brake fluid comes out. While the
assistant maintains pressure on the brake pedal,
tighten the bleeder screw. ^
Repeat until clear, bubble-free fluid comes out.
^ Refill the brake master cylinder reservoir as necessary.
10. Tighten the RH front brake caliper bleeder screw to 10 Nm (89 lb-in), remove the rubber hose
and install the bleeder screw cap. 11. Repeat Steps 7 through 10 for the LH front brake caliper
bleeder screw.
^ Tighten the LH front brake caliper bleeder screw to 10 Nm (89 lb-in).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 6110
13480A, 9818A8)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2455 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 6116
13480A, 9818A8)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2455 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair
> Brake Pedal and Bracket > Page 6119
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: Do not service the brake pedal without first removing the stoplamp switch and speed
control deactivator switch. These
switches must be removed with the brake pedal in the at-rest position. Switch plungers must be
compressed for the switch to rotate in the bracket. Attempting to remove the switch when the
plunger is extended (during pedal apply) will result in damage to the switch.
Remove the stoplamp switch. For additional information, refer to Lighting and Horns.
3. Remove the speed control deactivator switch.
For additional information, refer to Cruise Control.
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 disconnect the steering column shaft from the
steering column. 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 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair
> Brake Pedal and Bracket > Page 6120
4. Install the 2 brake pedal bracket bolts.
^ Tighten to 22 Nm (16 lb-ft).
5. Install the 3 accelerator pedal bracket nuts.
^ Tighten to 7 Nm (62 lb-in).
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 column to the steering column shaft and install the bolt.
^ Tighten to 30 Nm (22 lb-ft).
11. Position the steering column opening cover and install the 2 screws.
12. CAUTION: Do not press, pull or otherwise move the brake pedal while installing the stoplamp
switch or the speed control deactivator
switch. These switches must be installed with the booster push rod attached to the brake pedal and
with the brake pedal in the at-rest position. Installing these switches with the brake pedal in any
other position will result in incorrect adjustment and may damage the switches.
Install the stoplamp switch.
13. Install the speed control deactivator switch. 14. Repower the SRS. For additional information,
refer to Air Bag Systems.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair
> Brake Pedal and Bracket > Page 6121
Brake Pedal Assy: 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 lb-in).
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 6131
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 (V8-4.6L (2008))
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 6132
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 6138
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 (V8-4.6L (2008))
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 6139
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 (V8-4.6L (2008))
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
Removal
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification.
Additionally, do not use brake fluid that has been previously drained. Following these instructions
will help prevent system contamination, brake component damage and the risk of serious 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 serious 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. Remove the wheel and tire. 2. Remove the brake flexible hose flow bolt and position the brake
hose aside.
^ Discard the 2 copper washers.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Caliper Removal and Installation, Front > Page 6142
^ 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. Position the brake caliper and install the 2 guide pin bolts.
^ Tighten to 72 Nm (53 lb-ft).
2. Using 2 new copper washers, position the brake hose and install the brake hose flow bolt.
^ Tighten to 35 Nm (26 lb-ft).
3. Bleed the brake caliper. 4. Install the wheel and tire.
^ Apply brakes several times to verify correct brake operation.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Caliper Removal and Installation, Front > Page 6143
Brake Caliper: Service and Repair Caliper Removal and Installation, Rear
Brake Caliper
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Caliper Removal and Installation, Front > Page 6144
Removal
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification.
Additionally, do not use brake fluid that has been previously drained. Following these instructions
will help prevent system contamination, brake component damage and the risk of serious 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 serious 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. Remove the wheel and tire. 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 lb-ft).
3. Using 2 new copper washers, position the brake hose and install the brake hose flow bolt.
^ Tighten to 35 Nm (26 lb-ft).
4. Bleed the brake caliper. 5. Install the wheel and tire.
^ Apply brakes several times to verify correct brake operation.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Caliper Removal and Installation, Front > Page 6145
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 lb-ft).
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 6154
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 (V8-4.6L (2008))
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 6155
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 6161
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 (V8-4.6L (2008))
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 6162
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 (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Page 6163
Brake Pad: Specifications
Brake Pads
Maximum taper wear (in any direction)
................................................................................................................................................ 3.0 mm
(0.118 in) Minimum thickness ..............................................................................................................
................................................................. 3.0 mm (0.118 in)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front > Page 6166
Removal
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification.
Additionally, do not use brake fluid that has been previously drained. Following these instructions
will help prevent system contamination, brake component damage and the risk of serious 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 serious personal injury.
WARNING: Always install new brake shoes or pads at both ends of an axle to reduce the
possibility of brakes pulling vehicle to one side. Failure to follow this instruction may result in
uneven braking and serious 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. Remove the wheel and tire.
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. 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 or damage to components may
occur.
Using a C-clamp and a worn brake pad, compress the disc brake caliper pistons into the caliper.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front > Page 6167
3. Position the brake caliper and install the 2 guide pin bolts.
^ Tighten to 72 Nm (53 lb-ft).
4. Fill the brake master cylinder reservoir with clean brake fluid. 5. Install the wheel and tire.
^ Apply brakes several times to verify correct brake operation.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front > Page 6168
Brake Pad: Service and Repair Rear
Brake Pads
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front > Page 6169
Removal
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification.
Additionally, do not use brake fluid that has been previously drained. Following these instructions
will help prevent system contamination, brake component damage and the risk of serious 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 serious personal injury.
WARNING: Always install new brake shoes or pads at both ends of an axle to reduce the
possibility of brakes pulling vehicle to one side. Failure to follow this instruction may result in
uneven braking and serious 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. Remove the wheel and tire.
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. 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 or damage to components may
occur.
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 lb-ft).
4. Fill the brake master cylinder reservoir with clean, specified brake fluid. 5. Install the wheel and
tire.
^ Apply brakes several times to verify correct brake operation.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Specifications
Brake Rotor/Disc: Specifications
Front Brake Disc
Minimum thickness ..............................................................................................................................
............................................... 28.5 mm (1.122 in) Minimum thickness to machine
..........................................................................................................................................................
29.10 mm (1.145 in)
Rear Brake Disc
Minimum thickness ..............................................................................................................................
................................................ 11.0 mm (0.433 in) Minimum thickness to machine
............................................................................................................................................................
11.6 mm (0.456 in)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
NOTE: Do not use a bench lathe to machine the brake discs.
NOTE: Read the entire operating manual and/or 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 tube 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, carry out the steps in the following
order.
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 marks and install the brake disc on the hub.
3. Machine the brake disc using an on-vehicle brake lathe. Carry out the steps in the following
order.
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 in), maximum is 0.08 mm (0.003 in).
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 in). 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 carry
out the steps in the following order:
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.
Install the brake caliper and brake caliper anchor bracket.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Procedures > Page 6175
Brake Rotor/Disc: Removal and Replacement
Disc Removal and Installation, Front
Brake Disc
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 (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Procedures > Page 6176
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 lb-ft).
Disc Removal and Installation, Rear
Brake Disc
Removal
1. Remove the wheel and tire.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Procedures > Page 6177
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 lb-ft).
4. Install the wheel and tire.
^ Apply brakes several times to verify correct brake operation.
Shield Removal and Installation, Front
Brake Disc Shield
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Procedures > Page 6178
Removal and Installation
1. Remove the brake disc. 2. Remove and discard the 4 brake disc shield bolts.
^ To install, tighten new bolts to 8 Nm (71 lb-in).
3. Remove the brake disc shield. 4. To install, reverse the removal procedure.
Shield Removal and Installation, Rear
Brake Disc Shield
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Procedures > Page 6179
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 lb-in).
2. Install the parking brake shoes.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 6189
13480A, 9818A8)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2455 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 6195
13480A, 9818A8)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2455 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 6201
13480A, 9818A8)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2455 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > ABS Hydraulic Control Unit (HCU) Bleeding
Brake Bleeding: Service and Repair ABS Hydraulic Control Unit (HCU) Bleeding
ABS Hydraulic Control Unit (HCU) Bleeding
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification.
Additionally, do not use brake fluid that has been previously drained. Following these instructions
will help prevent system contamination, brake component damage and the risk of serious 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 serious personal injury.
WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master
cylinder may be damaged if operated without fluid, resulting in degraded braking performance.
Failure to follow this instruction may result in serious 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.
NOTE: This procedure is only required when a new hydraulic control unit (HCU) is installed.
NOTE: When any part of the hydraulic system is disconnected for repair or installation of new
components, air can get into the system and cause spongy brake pedal action. This requires
bleeding of the hydraulic system after it is correctly connected. The hydraulic system can be bled
manually or with pressure bleeding equipment.
1. NOTE: Carrying out the System Bleed function drives trapped air from the HCU. Subsequent
bleeding removes the air from the brake hydraulic
system through the bleeder screws.
NOTE: Adequate voltage to the HCU module is required during the anti-lock control portion of the
system bleed.
Connect the scan tool to the vehicle.
2. Access the ABS HCU bleed function and follow the directions on the scan tool. 3. Manually
bleed the brake hydraulic system. 4. Repeat the procedure carrying out a total of 2 scan tool cycles
and 2 manual bleed cycles.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > ABS Hydraulic Control Unit (HCU) Bleeding > Page 6204
Brake Bleeding: Service and Repair Component Bleeding
Component Bleeding
Master Cylinder
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification.
Additionally, do not use brake fluid that has been previously drained. Following these instructions
will help prevent system contamination, brake component damage and the risk of serious 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 serious personal injury.
WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master
cylinder may be damaged if operated without fluid, resulting in degraded braking performance.
Failure to follow this instruction may result in serious personal injury.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If spilled, wipe up immediately
before damage to the painted or plastic surface occurs.
NOTE: When any part of the hydraulic system has been disconnected for repair or installation of
new components, air can enter the system and cause spongy brake pedal action. This requires
bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can
be bled manually or with pressure bleeding equipment.
NOTE: When 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 entering the system.
1. Disconnect the brake tubes from the master cylinder.
2. Install 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 (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > ABS Hydraulic Control Unit (HCU) Bleeding > Page 6205
3. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes, without air
bubbles. 4. Remove the short brake tubes and install the brake outlet tubes. 5. Bleed each brake
tube at the brake master cylinder as follows:
1 Have an assistant pump the brake pedal at least 2 times and then hold firm pressure on the
brake pedal.
2 Loosen the rearmost brake tube fitting until a stream of brake fluid comes out. While the assistant
maintains pressure on the brake pedal, tighten 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.
5 Tighten the master cylinder brake tube fittings to 18 Nm (13 lb-ft).
6. Bleed the brake system.
Brake Caliper
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification.
Additionally, do not use brake fluid that has been previously drained. Following these instructions
will help prevent system contamination, brake component damage and the risk of serious 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 serious personal injury.
WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master
cylinder may be damaged if operated without fluid, resulting in degraded braking performance.
Failure to follow this instruction may result in serious personal injury.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If spilled, wipe up immediately
before damage to the painted or plastic surface occurs.
NOTE: It is not necessary to do a complete brake system bleed if only the brake caliper was
disconnected or installed new.
1. Remove the brake caliper bleeder screw cap and place a box-end wrench on the bleeder screw.
Attach a rubber drain hose to the bleeder screw and
submerge the free end of the hose 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.
Loosen the bleeder screw until a stream of brake fluid comes out. While the assistant maintains
pressure on the brake pedal, tighten the bleeder
screw. ^
Repeat until clear, bubble-free fluid comes out.
^ Refill the brake master cylinder reservoir as necessary.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > ABS Hydraulic Control Unit (HCU) Bleeding > Page 6206
4. Tighten the brake caliper bleeder screw, remove the rubber hose and install the bleeder screw
cap.
^ Tighten the front brake caliper bleeder screw to 10 Nm (89 lb-in).
^ Tighten the rear brake caliper bleeder screw to 22 Nm (16 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > ABS Hydraulic Control Unit (HCU) Bleeding > Page 6207
Brake Bleeding: Service and Repair Brake System Bleeding
Brake System Bleeding
Pressure Bleed
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification.
Additionally, do not use brake fluid that has been previously drained. Following these instructions
will help prevent system contamination, brake component damage and the risk of serious 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 serious personal injury.
WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master
cylinder may be damaged if operated without fluid, resulting in degraded braking performance.
Failure to follow this instruction may result in serious 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.
NOTE: When any part of the hydraulic system has been disconnected for repair or installation of
new components, air can get into the system and cause spongy brake pedal action. This requires
bleeding of the hydraulic system after it has been correctly connected.
NOTE: Pressure bleed the brake system at 207-345 kPa (30-50 psi).
1. NOTE: If the hydraulic control unit (HCU) or any component upstream of the HCU are installed
new, carry out the Brake System Pressure
Bleeding procedure, then the anti-lock HCU bleed procedure, followed by another Brake System
Bleed Procedure.
Clean all the dirt from around the brake fluid reservoir cap and remove the cap. Fill the brake
master cylinder reservoir with clean, specified brake fluid.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > ABS Hydraulic Control Unit (HCU) Bleeding > Page 6208
2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers
of pressure bleeding equipment. Follow the
instructions of the manufacturer when installing the adapter.
Install the bleeder adapter to the brake master cylinder reservoir and attach the bleeder tank hose
to the fitting on the adapter.
3. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake
fluid to complete the bleeding operation.
Remove the RH rear brake caliper bleeder cap and place a box-end wrench on the bleeder screw.
Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a
container partially filled with clean, specified brake fluid.
4. Open the valve on the bleeder tank. 5. Loosen the RH rear brake caliper bleeder screw. Leave
open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw.
^ Press and release the parking brake 5 times.
^ Repeat until clear, bubble-free fluid comes out.
6. Tighten the RH rear brake caliper bleeder screw to 22 Nm (16 lb-ft), remove the rubber hose and
install the bleeder screw cap. 7. Repeat Steps 5 and 6 for the LH rear brake caliper.
^ Tighten the LH rear brake caliper bleeder screw to 22 Nm (16 lb-ft).
8. Continue bleeding the front of the system, going in order from the RH front brake caliper and
then to the LH front brake caliper.
^ Tighten the front brake caliper bleeder screws to 10 Nm (89 lb-in).
9. Close the bleeder tank valve. Remove the tank hose from the adapter and remove the adapter.
Fill the reservoir with clean, specified brake fluid
and install the reservoir cap.
Manual Bleeding
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification.
Additionally, do not use brake fluid that has been previously drained. Following these instructions
will help prevent system contamination, brake component damage and the risk of serious 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 serious personal injury.
WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master
cylinder may be damaged if operated without fluid, resulting in degraded braking performance.
Failure to follow this instruction may result in serious 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.
NOTE: When any part of the hydraulic system is disconnected for repair or installation of new
components, air can get into the system and cause spongy brake pedal action. This requires
bleeding of the hydraulic system after it is correctly connected. The hydraulic system can be bled
manually or with pressure bleeding equipment.
1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master
cylinder reservoir with clean, specified brake fluid.
2. NOTE: Bleed the brake system from the longest to the shortest brake line.
Remove the RH rear brake caliper bleeder screw cap and place a box-end wrench on the bleeder
screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a
container partially filled with clean, specified brake fluid.
3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 4.
Loosen the RH rear brake caliper bleeder screw until a stream of brake fluid comes out. While the
assistant maintains pressure on the brake pedal,
tighten the bleeder screw.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > ABS Hydraulic Control Unit (HCU) Bleeding > Page 6209
^ Repeat until clear, bubble-free fluid comes out.
^ Refill the brake master cylinder reservoir as necessary.
5. Tighten the RH rear brake caliper bleeder screw to 22 Nm (16 lb-ft), remove the rubber hose and
install the bleeder screw cap. 6. Repeat Steps 2 through 5 for the LH rear brake caliper bleeder
screw.
^ Tighten the LH rear brake caliper bleeder screw to 22 Nm (16 lb-ft).
7. Remove the RH front brake caliper bleeder screw cap and place a box-end wrench on the
bleeder screw. Attach a rubber drain hose to the bleeder
screw and submerge the free end of the hose in a container partially filled with clean, specified
brake fluid.
8. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 9.
Loosen the RH front brake caliper bleeder screw until a stream of brake fluid comes out. While the
assistant maintains pressure on the brake pedal,
tighten the bleeder screw. ^
Repeat until clear, bubble-free fluid comes out.
^ Refill the brake master cylinder reservoir as necessary.
10. Tighten the RH front brake caliper bleeder screw to 10 Nm (89 lb-in), remove the rubber hose
and install the bleeder screw cap. 11. Repeat Steps 7 through 10 for the LH front brake caliper
bleeder screw.
^ Tighten the LH front brake caliper bleeder screw to 10 Nm (89 lb-in).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 6218
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 (V8-4.6L (2008))
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 6219
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 6225
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 (V8-4.6L (2008))
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 6226
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 (V8-4.6L (2008))
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
Removal
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification.
Additionally, do not use brake fluid that has been previously drained. Following these instructions
will help prevent system contamination, brake component damage and the risk of serious 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 serious 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. Remove the wheel and tire. 2. Remove the brake flexible hose flow bolt and position the brake
hose aside.
^ Discard the 2 copper washers.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Caliper Removal and Installation, Front > Page 6229
^ 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. Position the brake caliper and install the 2 guide pin bolts.
^ Tighten to 72 Nm (53 lb-ft).
2. Using 2 new copper washers, position the brake hose and install the brake hose flow bolt.
^ Tighten to 35 Nm (26 lb-ft).
3. Bleed the brake caliper. 4. Install the wheel and tire.
^ Apply brakes several times to verify correct brake operation.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Caliper Removal and Installation, Front > Page 6230
Brake Caliper: Service and Repair Caliper Removal and Installation, Rear
Brake Caliper
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Caliper Removal and Installation, Front > Page 6231
Removal
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification.
Additionally, do not use brake fluid that has been previously drained. Following these instructions
will help prevent system contamination, brake component damage and the risk of serious 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 serious 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. Remove the wheel and tire. 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 lb-ft).
3. Using 2 new copper washers, position the brake hose and install the brake hose flow bolt.
^ Tighten to 35 Nm (26 lb-ft).
4. Bleed the brake caliper. 5. Install the wheel and tire.
^ Apply brakes several times to verify correct brake operation.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Caliper Removal and Installation, Front > Page 6232
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 lb-ft).
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch >
Component Information > Locations
Brake Fluid Level Sensor/Switch: Locations
View 151-1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch >
Component Information > Locations > Page 6239
View 151-4
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch >
Component Information > Locations > Page 6240
C124
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Front
Brake Hose/Line: Service and Repair Front
Brake Flexible Hose
Removal and Installation
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification.
Additionally, do not use brake fluid that has been previously drained. Following these instructions
will help prevent system contamination, brake component damage and the risk of serious 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 serious 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. Remove the brake flexible hose flow bolt and discard the 2 copper washers.
^ To install, tighten to 35 Nm (26 lb-ft).
^ Use 2 new copper washers.
2. Disconnect the brake tube fitting from the brake flexible hose.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Front > Page 6245
^ To install, tighten to 18 Nm (13 lb-ft).
3. Remove the brake flexible hose retaining clip and the brake flexible hose. 4. To install, reverse
the removal procedure.
^ Bleed the brake system.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Front > Page 6246
Brake Hose/Line: Service and Repair Rear
Brake Flexible Hose
Removal and Installation
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification.
Additionally, do not use brake fluid that has been previously drained. Following these instructions
will help prevent system contamination, brake component damage and the risk of serious 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 serious 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. Remove the wheel and tire. 2. Remove the brake caliper flow bolt and discard the 2 copper
washers.
^ To install, tighten to 35 Nm (26 lb-ft).
3. Disconnect the brake tube fitting from the brake flexible hose.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Front > Page 6247
^ To install, tighten to 18 Nm (13 lb-ft).
4. Remove the brake flexible hose bracket bolt and the brake hose.
^ To install, tighten to 20 Nm (15 lb-ft).
5. To install, reverse the removal procedure.
^ Bleed the brake caliper.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Assembly, Traction Control
> Component Information > Service and Repair
Hydraulic Assembly: Service and Repair
Hydraulic Control Unit (HCU)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Assembly, Traction Control
> Component Information > Service and Repair > Page 6251
Removal and Installation
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification.
Additionally, do not use brake fluid that has been previously drained. Following these instructions
will help prevent system contamination, brake component damage and the risk of serious 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 serious 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 battery tray. 3. Disconnect the ABS module
electrical connector.
4. NOTE: The brake tubes must be installed in the same location as removed.
Remove the 2 master cylinder primary and secondary brake tube-to-hydraulic control unit (HCU)
fittings and position both brake tubes aside. ^
To install, tighten to 23 Nm (17 lb-ft).
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 lb-ft).
6. Remove the 3 HCU bracket-to-frame nuts.
^ To install, tighten to 23 Nm (17 lb-ft).
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Assembly, Traction Control
> Component Information > Service and Repair > Page 6252
^ To install, tighten to 18 Nm (13 lb-ft).
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 lb-in).
10. Remove the HCU bracket-to-HCU bolt and the HCU bracket.
^ To install, tighten to 9 Nm (80 lb-in).
11. To install, reverse the removal procedure.
^ Bleed the brake system.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 from the master cylinder. 2. Plug the outlet ports of the master
cylinder. 3. Apply the brakes. If brake pedal height cannot be maintained, the brake master cylinder
has an internal leak and a new brake master cylinder must
be installed.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Testing and Inspection > Brake Master Cylinder - Bypass Condition > Page 6257
Brake Master Cylinder: Testing and Inspection Brake Master Cylinder - Compensator Port
Brake Master Cylinder - Compensator Port
The purpose of the compensator ports in the brake master cylinder is to: ^
supply additional brake fluid from the brake master cylinder reservoir needed by the brake system
due to brake lining wear.
^ allow brake fluid to return to the brake master cylinder reservoir when the brakes are released.
The returning brake fluid creates a slight turbulence in the brake master cylinder reservoir. This is a
normal condition and indicates that the compensator ports are not clogged.
Clogged compensator ports may cause the brakes to hang up or not fully release. If clogged
compensator ports are suspected, proceed as follows: 1. With the vehicle in NEUTRAL, position it
on a hoist. Refer to Maintenance/Service and Repair. 2. With the brakes released, attempt to rotate
each wheel and check for any brake drag.
^ If an excessive amount of brake drag exists at all 4 wheels, continue with the test.
^ If an excessive amount of brake drag exists at only one wheel, it indicates a possible seized
brake caliper, brake wheel cylinder or parking brake component. Repair or install new components
as necessary.
3. Check the brake stoplamp switch and the brake pedal free play to verify that the brake pedal is
not partially applied. 4. Loosen the brake master cylinder nuts and position the brake master
cylinder away from the brake booster. 5. With the brakes released, attempt to rotate each wheel
and check for any brake drag.
^ If the brake drag is no longer present, install a new brake booster.
^ If the brake drag is still present, install a new master cylinder.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Testing and Inspection > Page 6258
Brake Master Cylinder: Service and Repair
Brake Master Cylinder
Removal and Installation
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification.
Additionally, do not use brake fluid that has been previously drained. Following these instructions
will help prevent system contamination, brake component damage and the risk of serious 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 serious 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. Use a suitable suction device to drain the brake master cylinder reservoir. 2. Disconnect the
brake fluid level warning switch electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Testing and Inspection > Page 6259
3. Disconnect the 2 brake tube fittings from the brake master cylinder.
^ To install, tighten to 18 Nm (13 lb-ft).
4. Remove the 2 nuts, the brake master cylinder and the square cut seal.
^ To install, tighten to 25 Nm (18 lb-ft).
5. 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 (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures
Parking Brake Cable: Procedures
Parking Brake Cable Tension Release
1. Remove the LH cowl side trim panel. For additional information, refer to 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 in) x 150 mm (5.9 in)
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 (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 6265
Parking Brake Cable: Removal and Replacement
Parking Brake Cable - Rear, LH
Parking 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 wire form bolt.
^ To install, tighten to 23 Nm (17 lb-ft).
4. Remove the bracket bolt.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 6266
^ To install, tighten to 23 Nm (17 lb-ft).
5. Disconnect the intermediate cable from the LH rear cable at the cable equalizer. 6. Disconnect
the front of the LH rear cable conduit at the frame bracket. 7. Disconnect the LH parking brake
cable from the parking brake lever and remove the cable. 8. To install, reverse the removal
procedure.
^ Test the parking brake system for correct operation.
Parking Brake Cable - Rear, RH
Parking Brake Cable - Rear, RH
Removal and Installation
1. Release the parking brake cable tension.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 6267
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 lb-ft).
4. Remove the 2 parking brake cable bracket-to-crossmember bolts.
^ To install, tighten to 15 Nm (11 lb-ft).
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.
Parking Brake Cable - Front
Parking Brake Cable - Front
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 6268
Removal and Installation
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 6269
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. 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 lb-in).
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 lb-ft).
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.
Parking Brake Cable - Intermediate
Parking Brake Cable - Intermediate
NOTE: The equalizer is integral to the intermediate cable.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Procedures > Page 6270
Removal and Installation
1. Release the tension on the parking brake cable. 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 (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component
Information > Service and Repair > Page 6274
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 lb-in).
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 lb-ft).
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 (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Adjustments
Parking Brake Shoe: Adjustments
Parking Brake Shoe Adjustment
1. NOTE: Make sure the parking brake is fully released.
Using the release handle, release the parking brake control.
2. Remove the rear brake disc. 3. Using the special tool, measure the inside diameter of the drum
portion of the rear brake disc and set the locking screw.
^ Record the measurement.
4. Place the special tool over the widest diameter of the parking brake shoes.
5. Adjust the parking brake shoe clearance to 0.54 mm (0.021 in) less than the inside diameter of
the drum portion of the rear brake disc.
^ Rotate the parking brake shoe adjuster to achieve the correct parking brake shoe-to-brake disc
clearance.
6. Install the rear brake disc. 7. Test the parking brake for normal operation.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Adjustments > Page 6278
Parking Brake Shoe: Service and Repair
Parking Brake Shoes
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. For additional information, refer to Parking Brake
Cable Tension Release.
2. Remove the rear brake disc. 3. Remove the parking brake shoe adjusting screw. 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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Adjustments > Page 6279
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. Adjust the parking brake shoe. 6. Reload the tension on the parking brake cable.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch >
Component Information > Locations
Parking Brake Warning Switch: Locations
View 151-18
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch >
Component Information > Locations > Page 6283
View 151-19
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch >
Component Information > Locations > Page 6284
C2015
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor >
Component Information > Locations
Brake Booster Vacuum Sensor: Locations
View 151-2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor >
Component Information > Locations > Page 6289
View 151-5
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor >
Component Information > Locations > Page 6290
C149
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Specifications
Vacuum Brake Booster: Specifications
Torque Specifications
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Specifications > Page 6294
Vacuum Brake Booster: Description and Operation
Brake Booster
The power brake actuation system consists of the following components: ^
Brake booster assembly
^ Brake booster vacuum fitting
Pedal pressure is amplified by the brake booster.
The brake booster uses engine vacuum from the intake manifold. The low pressure in the intake
manifold is applied to a rubber diaphragm on the vacuum side of the brake booster chamber, which
then pulls the piston rod in when the brakes are applied to supply a power assist. The piston rod is
connected to the brake pedal.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Specifications > Page 6295
Vacuum Brake Booster: Testing and Inspection
Brake Booster
1. Disconnect the check valve from the brake booster. 2. Apply the parking brake, start the engine
and place the transmission in NEUTRAL. 3. Verify that manifold vacuum is available at the check
valve with the engine at idle speed and the transmission in NEUTRAL.
^ If manifold vacuum is available, stop the engine, connect the check valve and continue with Step
5.
^ If manifold vacuum is not available, continue with Step 4.
4. Disconnect the check valve from the vacuum hose and verify that manifold vacuum is available
at the hose with the engine at idle speed and the
transmission in NEUTRAL. ^
If manifold vacuum is available, stop the engine, install a new check valve and continue with Step
5.
^ If manifold vacuum is not available, stop the engine, connect the vacuum hose to the check valve
and diagnose the no vacuum condition.
5. Apply the brake pedal several times to exhaust all vacuum from the system. 6. Apply the brake
pedal and hold it in the applied position. Start the engine and verify that the brake pedal moves
downward after the engine starts.
^ If the brake pedal moves, the brake booster is operating correctly.
^ If the brake pedal does not move, install a new brake booster.
7. 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 lb) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Specifications > Page 6296
Vacuum Brake Booster: Service and Repair
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.
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 DTCs being set.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Specifications > Page 6297
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 lb-ft).
7. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 in case manifold vacuum is lost during sustained full
throttle operation. 1. Disconnect the vacuum booster hose from the check valve. 2. Apply the
parking brake, start the engine and place the transmission in NEUTRAL. 3. Verify that manifold
vacuum is available at the check valve end of the vacuum hose with the engine at idle speed and
the transmission in
NEUTRAL. ^
If manifold vacuum is available, stop the engine, connect the vacuum hose to the check valve and
continue this test.
^ If manifold vacuum is not available, stop the engine, connect the vacuum hose to the check valve
and diagnose the no vacuum condition.
4. Connect the vacuum hose to the check valve and run the engine for at least 10 seconds. 5.
Operate the brake pedal to check for power assist.
^ If power assist is present, continue with this test.
^ If power assist is not present, refer to Brake Booster Component Test. See: Testing and
Inspection/Component Tests and General Diagnostics/Brake Booster
6. NOTE: Do not remove the brake booster check valve from the brake booster in this step.
Stop the engine and disconnect the vacuum booster hose from the brake booster check valve.
7. Apply the brake and verify that there is enough vacuum retained in the brake booster for at least
one power-assisted brake application.
^ If there is enough vacuum for at least one power-assisted brake application, the check valve is
functioning correctly.
^ If there is not enough vacuum for at least one power-assisted brake application, continue with this
test.
8. Inspect the brake booster for any signs of damage that could cause a leak.
^ If any damage is found, install a new brake booster and repeat this test.
^ If no damage is found, install a new check valve.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component
Information > Locations
View 151-13
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component
Information > Locations > Page 6305
C239
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations
Electronic Brake Control Module: Locations
View 151-2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations > Page 6310
View 151-5
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations > Page 6311
Electronic Brake Control Module: Diagrams
C155 (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations > Page 6312
C155 (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Locations > Page 6313
Electronic Brake Control Module: Service and Repair
Anti-Lock Brake System (ABS) Module
Removal and Installation
CAUTION: Electronic modules are sensitive to electrical charges. The anti-lock brake system
(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 Programmable Module Installation in Information Bus (Module Configuration).
1. Remove the hydraulic control unit (HCU). 2. Remove the 4 screws and the ABS module.
^ To install, tighten to 2 Nm (18 lb-in).
3. CAUTION: Make sure that the anti-lock brake system (ABS) module is properly seated to the
hydraulic control unit (HCU) and that the
torque of the ABS module screws is correct, or damage to the components can occur.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake
Control Module > Component Information > Locations
View 151-13
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake
Control Module > Component Information > Locations > Page 6317
C239
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > ABS
Sensor Block > Component Information > Locations
View 151-17
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > ABS
Sensor Block > Component Information > Locations > Page 6322
C3073
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > ABS
Sensor Block > Component Information > Locations > Page 6323
ABS Sensor Block: Service and Repair
Stability Control Sensor Cluster
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > ABS
Sensor Block > Component Information > Locations > Page 6324
Removal and Installation
NOTE: When installing a new stability control sensor cluster, the ABS module must be calibrated.
Follow the scan tool directions for the calibration procedures.
1. Remove the pin-type retainer and the LH floor console finish panel. 2. Remove the 2 bolts, 2
nuts and the LH instrument panel brace.
^ To install, tighten to 9 Nm (80 lb-in).
3. Remove the 2 bolts and LH floor 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 lb-in).
7. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Booster Vacuum Sensor > Component Information > Locations
Brake Booster Vacuum Sensor: Locations
View 151-2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Booster Vacuum Sensor > Component Information > Locations > Page 6328
View 151-5
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Booster Vacuum Sensor > Component Information > Locations > Page 6329
C149
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations
Brake Fluid Level Sensor/Switch: Locations
View 151-1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations > Page 6333
View 151-4
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations > Page 6334
C124
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral
Accelerometer > Component Information > Service and Repair > Page 6338
Removal and Installation
NOTE: When installing a new stability control sensor cluster, the ABS module must be calibrated.
Follow the scan tool directions for the calibration procedures.
1. Remove the pin-type retainer and the LH floor console finish panel. 2. Remove the 2 bolts, 2
nuts and the LH instrument panel brace.
^ To install, tighten to 9 Nm (80 lb-in).
3. Remove the 2 bolts and LH floor 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 lb-in).
7. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking
Brake Warning Switch > Component Information > Locations
Parking Brake Warning Switch: Locations
View 151-18
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking
Brake Warning Switch > Component Information > Locations > Page 6342
View 151-19
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking
Brake Warning Switch > Component Information > Locations > Page 6343
C2015
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
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 (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Locations
View 151-13
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Locations > Page 6350
C280
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Locations > Page 6351
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 lb-in).
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Locations > Page 6352
5. Disconnect the stability traction control switch electrical connector and remove the stability
traction control switch from the instrument panel
center finish panel.
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front
Wheel Speed Sensor: Locations Wheel Speed Sensor, Left Front
View 151-2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 6357
View 151-5
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 6358
Wheel Speed Sensor: Locations Wheel Speed Sensor, Right Front
View 151-2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 6359
View 151-5
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 6360
Wheel Speed Sensor: Locations Wheel Speed Sensor, Left Rear
View 151-22
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 6361
View 151-27
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 6362
Wheel Speed Sensor: Locations Wheel Speed Sensor, Right Rear
View 151-24
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 6363
View 151-27
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front
C150
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 6366
C160
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 6367
C440
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 6368
C426
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
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. 4. Remove the wheel speed sensor harness
pin-type retainers. 5. Remove the wheel speed sensor bolt.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6371
^ To install, tighten to 17 Nm (13 lb-ft).
6. Remove the wheel speed sensor and the harness. 7. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6372
Wheel Speed Sensor: Service and Repair 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 lb-in).
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Service and Repair
Yaw Rate Sensor: Service and Repair
Stability Control Sensor Cluster
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Service and Repair > Page 6376
Removal and Installation
NOTE: When installing a new stability control sensor cluster, the ABS module must be calibrated.
Follow the scan tool directions for the calibration procedures.
1. Remove the pin-type retainer and the LH floor console finish panel. 2. Remove the 2 bolts, 2
nuts and the LH instrument panel brace.
^ To install, tighten to 9 Nm (80 lb-in).
3. Remove the 2 bolts and LH floor 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 lb-in).
7. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Part 1
Part 2
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 (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations
Neutral Safety Switch: Locations
View 151-7
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations > Page 6386
View 151-11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations > Page 6387
C167
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Starter Relay
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Starter Relay > Page 6393
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Testing and Inspection > Run/Start Relay
Starter Relay: Testing and Inspection Run/Start Relay
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Testing and Inspection > Run/Start Relay > Page 6396
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Testing and Inspection > Run/Start Relay > Page 6397
Starter Relay: Testing and Inspection Starter Relay
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Testing and Inspection > Run/Start Relay > Page 6398
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair
Battery Cable: Service and Repair
BATTERY CABLES
LH Engine Connections (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair
> Page 6403
LH Engine Connections (Part 2)
RH Engine Connections
Removal and Installation
1. Disconnect the battery. 2. With the vehicle in NEUTRAL, position it on a hoist. 3. Remove the nut
and position the battery cable body ground terminal aside.
- To install, tighten to 9 Nm (80 lb-in).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair
> Page 6404
4. Disconnect the battery cable electrical connector. 5. Remove the 2 battery cable locators from
the battery tray. 6. Remove the battery junction box (BJB) terminal nuts.
- To install, tighten to 9 Nm (80 lb-in).
7. Position the generator harness terminal aside. 8. Position the BJB terminal aside. 9. Remove the
2 nuts and position the battery cable bracket aside.
- To install, tighten to 20 Nm (15 lb-ft).
10. Remove the nut and position the power steering (P/S) line bracket aside.
- To install, tighten to 12 Nm (9 lb-ft).
11. Remove the nut and position the battery cable engine front cover bracket aside.
- To install, tighten to 10 Nm (89 lb-in).
12. Disconnect the A/C compressor electrical connector. 13. Remove the A/C compressor electrical
connector harness locator. 14. Remove the bolt and position the battery cable right engine mount
bracket aside.
- To install, tighten to 20 Nm (15 lb-ft).
15. Remove the starter solenoid terminals protective cap. 16. Remove the nut and position the
starter solenoid positive cable terminal aside.
- To install, tighten to 12 Nm (9 lb-ft).
17. Remove the nut and position the starter solenoid wire cable terminal aside.
- To install, tighten to 6 Nm (53 lb-in).
18. Remove the nut and position the battery cable engine ground terminal aside.
- To install, tighten to 25 Nm (18 lb-ft).
19. Remove the battery cable. 20. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Electrical Specifications
Alternator: Electrical Specifications
Item.......................................................................................................................................................
..............................................................Specification
Generator
Generator amps............................................................................82/135 amps (max) (R)
1,800-6,000 generator rpm, approximately 500-2,000 engine rpm Voltage.........................................
..............................................................................................................................................................
..................12 volts
Generator
Load at 2,000 rpm................................................................................................................................
....................................................................82 amps No Load at 2,000 rpm........................................
.......................................................................................................................between 13.2 and 15.5
volts
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Electrical Specifications > Page 6410
Torque Specifications
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6413
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6414
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6415
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6416
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6417
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6418
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6419
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6420
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6421
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6422
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6423
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6424
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6425
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6426
Alternator: Connector Views
C102A
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6427
C102B
C102C
C1104A
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6428
C1104B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Page 6429
Alternator: Application and ID
Item.......................................................................................................................................................
..............................................................Specification
Generator
Generator pulley ratio...........................................................................................................................
..........................................................................2.72:1
Rating.......................................................................................................82/135 amp (max) (R)
1,800-6,000 generator rpm, approx. 500-2,000 engine rpm Voltage regulator type............................
..............................................................................................................................Electronic internal
with generator
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Page 6430
Alternator: Description and Operation
GENERATOR
The charging system consists of the following components:
- Generator
- Integral voltage regulator
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 (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Page 6431
Alternator: Service and Repair
GENERATOR
Part 1
Part 2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Page 6432
Removal and Installation
1. Disconnect the battery. 2. Remove the throttle body (TB). 3. Rotate the front end accessory drive
(FEAD) belt tensioner clockwise and position the FEAD aside. 4. Remove the 3 harness locators
from the generator bracket. 5. Remove the 4 bolts and the generator bracket.
- To install, tighten to 10 Nm (89 lb-in).
6. Loosen the 2 bolts and position the generator aside.
- To install, tighten to 25 Nm (18 lb-ft).
7. Disconnect the generator electrical connector. 8. Position the protective cover aside, remove and
discard the nut and position the generator B+ terminal aside.
- To install, tighten to 8 Nm (71 lb-in).
9. Remove the generator.
10. If necessary, remove the nut and the generator pulley.
- To install, tighten to 109 Nm (80 lb-ft).
11. To install, reverse the removal procedure.
- Install a new generator B+ terminal nut.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Part 1
Part 2
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 (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Locations
Neutral Safety Switch: Locations
View 151-7
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Locations > Page 6441
View 151-11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Locations > Page 6442
C167
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 normal operating
temperature).............................................................................................................0.5 volt
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Electrical Specifications > Page 6447
Torque Specifications
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Page 6448
Starter Motor: Locations
View 151-2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Page 6449
View 151-5
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Page 6450
Starter Motor: Diagrams
C197A
C197B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Page 6451
Starter Motor: Service and Repair
STARTER MOTOR
Removal and Installation
WARNING: Always disconnect the battery ground cable at the battery before disconnecting the
starter motor battery terminal lead. If a tool is shorted at the starter motor battery terminal, the tool
can quickly heat enough to cause a skin burn. Failure to follow this instruction may result in serious
personal injury.
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3.
Remove the starter 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 disconnect the ground cable from the stud bolt.
- To install, tighten to 20 Nm (15 lb-ft).
7. Remove the bolts, the stud bolt and the starter.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Page 6452
- To install, tighten to 25 Nm (18 lb-ft).
8. To install, reverse the removal procedure.
- Tighten the upper bolt before tightening the lower fasteners.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations >
Starter Relay
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations >
Starter Relay > Page 6457
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and
Inspection > Run/Start Relay
Starter Relay: Testing and Inspection Run/Start Relay
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and
Inspection > Run/Start Relay > Page 6460
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and
Inspection > Run/Start Relay > Page 6461
Starter Relay: Testing and Inspection Starter Relay
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and
Inspection > Run/Start Relay > Page 6462
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Power Point, Rear
C474
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Power Point, Rear > Page 6468
C3063
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Power Point, Rear > Page 6469
C3064
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Power Point, Rear > Page 6470
C3323
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Page 6471
Auxiliary Power Outlet: Service and Repair
POWER POINT
Special Tool(s)
Special Tool(s)
Removal
NOTE: Power point cover may differ depending on location.
1. Open the power point cover. 2. Install the special tool in one of the power point socket slots.
3. Position the special tool so that it engages in the adjacent slot.
4. Using the special tool, pull the power point socket out of the retainer.
5. Disconnect the electrical connector.
Installation
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Page 6472
1. Connect the electrical connector. 2. Slide the power point socket into the retainer.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Diagrams > Ignition Transformer Capacitor 1
C174
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Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Diagrams > Ignition Transformer Capacitor 1 > Page 6477
C194
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Diagrams > Ignition Transformer Capacitor 1 > Page 6478
C1196
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6483
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6484
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6485
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6486
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6487
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6488
Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6489
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6490
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6491
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6492
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6493
Fuse: Locations Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6496
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6497
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6498
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6499
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6500
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6501
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6502
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6503
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6504
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6505
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6506
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6507
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6508
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6511
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6512
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6513
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6514
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6515
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6516
Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6517
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6518
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6519
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6520
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6521
Fuse: Application and ID Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6526
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6527
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6528
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6529
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6530
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6531
Fuse Block: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6532
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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> Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6533
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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> Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6534
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6535
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6536
Fuse Block: Locations Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6539
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6540
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6541
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6542
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6543
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6544
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6545
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6546
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6547
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6548
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6549
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6550
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6551
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6552
Fuse Block: Connector Views
C1035A
C1035B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6553
C2280A (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6554
C2280A (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6555
C2280B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6556
C2280C
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6557
C2280D
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6558
C2280E
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6561
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6562
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6563
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6564
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6565
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6566
Fuse Block: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6567
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6568
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6569
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6570
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6571
Fuse Block: Application and ID Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component
Information > Testing and Inspection
Micro ISO Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component
Information > Testing and Inspection
Mini ISO Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422
Multiple Junction Connector: Diagrams C110-C422
C110
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6582
C133
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6583
C134
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6584
C139
C140
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6585
C146
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6586
C192
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6587
C210 (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6588
C210 (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6589
C211
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6590
C212
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6591
C214 (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6592
C214 (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6593
C215
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6594
C219
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6595
C237
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6596
C248
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6597
C260
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6598
C300
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6599
C311 (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6600
C311 (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6601
C312 (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6602
C312 (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6603
C317
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6604
C327
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6605
C340
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6606
C313
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6607
C314
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6608
C315
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6609
C316
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6610
C328 (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6611
C328 (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6612
C339
C405
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6613
C406
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6614
C408
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6615
C410
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6616
C411
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6617
C421
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6618
C422
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6619
Multiple Junction Connector: Diagrams C423-C4004
C423
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6620
C431
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6621
C432
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6622
C438
C465
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6623
C494
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6624
C495
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6625
C510
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6626
C511
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6627
C610
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6628
C700
C800
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6629
C913
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6630
C925
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6631
C3007
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6632
C3047
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6633
C3049
C3050
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6634
C3052
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6635
C3053
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6636
C3134
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6637
C3135 (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6638
C3135 (Part 2)
C3138
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6639
C4000
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C422 > Page 6640
C4004
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module >
Component Information > Service and Repair
Power Distribution Module: Service and Repair
SMART JUNCTION BOX (SJB)
Special Tool(s)
Special Tool(s)
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module >
Component Information > Service and Repair > Page 6644
Part 2
Removal
CAUTION:
- If the SJB is dropped, damage to the internal components may occur. A new SJB must be
installed.
- Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage
may result.
NOTE:
- Prior to the replacement of the module, it is necessary to upload the module configuration
information into the appropriate scan tool. This information must be downloaded into the new
module after installation.
- The tire pressure monitoring system (TPMS) functionality is integral to the SJB.
- 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 a manufacturing mode with 6 pre-set DTCs related to the TPMS. To clear the DTCs, successful
configuration of the SJB must occur, followed by successful TPMS sensor training, and a
successful self-test, including clearing of the DTCs. The DTCs are as follows: B2477 (Module Configuration Failure)
- B2868 (Left Front Tire Pressure Sensor Fault)
- B2869 (Right Front Tire Pressure Sensor Fault)
- B2870 (Right Rear Tire Pressure Sensor Fault)
- B2871 (Left Rear Tire Pressure Sensor Fault)
- C2780 (ECU in Manufacturer Sub-State)
1. NOTE: This step is necessary only if the SJB is being replaced.
Upload the module configuration information from the SJB.
2. Remove the driver door scuff plate. 3. Position the LH door opening weather seal aside.
4. 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.
5. Remove the 2 bolts and the parking brake release handle. 6. Disconnect the parking brake
switch electrical connector. 7. Release the hood release cable pushpin from the parking brake
control bracket. 8. Release the harness clip from the parking brake cable housing.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module >
Component Information > Service and Repair > Page 6645
9. 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.
10. 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 (then lift it upward to disengage the lower tangs from the instrument panel),
disconnect the 2 electrical connectors and position the bezel assembly aside.
11 If necessary, push the LH instrument panel side finish panel out and position it aside.
12. Through the headlight switch bezel opening, remove the 2 SJB bolts. 13. From under the
instrument panel, remove the third (lower right) SJB bolt.
14. 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.
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 be present
in order 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 lower, right 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. 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.
12. Position the LH door opening weather seal.
13. NOTE: If the SJB was not replaced, this is the last step that is necessary.
Install the driver door scuff plate.
14. NOTE:
- When successful, this step provides the calibration necessary for the SJB operation and clears
DTC B2477. The clearing of this DTC indicates the calibration data has been successfully
downloaded to the new SJB.
- When successful, this step also programs the remote transmitters into the new SJB. In the event
the remote transmitters do not program to the new SJB, all of the remote transmitters will need to
be present and refer to Locks, Remote Keyless Entry Transmitter Programming. This action will
program the remote transmitters into the new SJB. See: Accessories and Optional
Equipment/Antitheft and Alarm Systems/Keyless Entry/Keyless Entry Transmitter/Testing and
Inspection/Remote Keyless Entry Transmitter Programming
Download the SJB configuration information from the scan tool into the new SJB.
15. 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module >
Component Information > Service and Repair > Page 6646
16. NOTE: DTC C2780 will not clear if any of the pre-set DTCs are still present in the SJB. When
successful, this step will clear the DTC C2780.
Carry out the SJB on-demand self-test by clearing DTCs, and then retrieving DTCs to confirm all
DTCs have been cleared.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection
Micro ISO Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection
Mini ISO Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Module > Component Information > Service and Repair
Power Distribution Module: Service and Repair
SMART JUNCTION BOX (SJB)
Special Tool(s)
Special Tool(s)
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 6660
Part 2
Removal
CAUTION:
- If the SJB is dropped, damage to the internal components may occur. A new SJB must be
installed.
- Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage
may result.
NOTE:
- Prior to the replacement of the module, it is necessary to upload the module configuration
information into the appropriate scan tool. This information must be downloaded into the new
module after installation.
- The tire pressure monitoring system (TPMS) functionality is integral to the SJB.
- 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 a manufacturing mode with 6 pre-set DTCs related to the TPMS. To clear the DTCs, successful
configuration of the SJB must occur, followed by successful TPMS sensor training, and a
successful self-test, including clearing of the DTCs. The DTCs are as follows: B2477 (Module Configuration Failure)
- B2868 (Left Front Tire Pressure Sensor Fault)
- B2869 (Right Front Tire Pressure Sensor Fault)
- B2870 (Right Rear Tire Pressure Sensor Fault)
- B2871 (Left Rear Tire Pressure Sensor Fault)
- C2780 (ECU in Manufacturer Sub-State)
1. NOTE: This step is necessary only if the SJB is being replaced.
Upload the module configuration information from the SJB.
2. Remove the driver door scuff plate. 3. Position the LH door opening weather seal aside.
4. 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.
5. Remove the 2 bolts and the parking brake release handle. 6. Disconnect the parking brake
switch electrical connector. 7. Release the hood release cable pushpin from the parking brake
control bracket. 8. Release the harness clip from the parking brake cable housing.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 6661
9. 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.
10. 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 (then lift it upward to disengage the lower tangs from the instrument panel),
disconnect the 2 electrical connectors and position the bezel assembly aside.
11 If necessary, push the LH instrument panel side finish panel out and position it aside.
12. Through the headlight switch bezel opening, remove the 2 SJB bolts. 13. From under the
instrument panel, remove the third (lower right) SJB bolt.
14. 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.
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 be present
in order 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 lower, right 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. 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.
12. Position the LH door opening weather seal.
13. NOTE: If the SJB was not replaced, this is the last step that is necessary.
Install the driver door scuff plate.
14. NOTE:
- When successful, this step provides the calibration necessary for the SJB operation and clears
DTC B2477. The clearing of this DTC indicates the calibration data has been successfully
downloaded to the new SJB.
- When successful, this step also programs the remote transmitters into the new SJB. In the event
the remote transmitters do not program to the new SJB, all of the remote transmitters will need to
be present and refer to Locks, Remote Keyless Entry Transmitter Programming. This action will
program the remote transmitters into the new SJB. See: Accessories and Optional
Equipment/Antitheft and Alarm Systems/Keyless Entry/Keyless Entry Transmitter/Testing and
Inspection/Remote Keyless Entry Transmitter Programming
Download the SJB configuration information from the scan tool into the new SJB.
15. 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 6662
16. NOTE: DTC C2780 will not clear if any of the pre-set DTCs are still present in the SJB. When
successful, this step will clear the DTC C2780.
Carry out the SJB on-demand self-test by clearing DTCs, and then retrieving DTCs to confirm all
DTCs have been cleared.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6670
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6671
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6672
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6673
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6674
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6675
Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6676
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6677
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6678
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6679
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6680
Relay Box: Locations Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 6683
Relay Box: Diagrams Smart Junction Box (SJB)
C2280A (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6684
C2280A (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6685
C2280B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6686
C2280C
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6687
C2280D
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6688
C2280E
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6691
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6692
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6693
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6694
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6695
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6696
Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6697
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6698
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6699
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6700
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6701
Relay Box: Application and ID Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6706
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6707
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6708
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6709
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6710
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6711
Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6712
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6713
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6714
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6715
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6716
Relay Box: Locations Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Diagrams > Battery Junction Box (BJB) > Page 6719
Relay Box: Diagrams Smart Junction Box (SJB)
C2280A (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Diagrams > Battery Junction Box (BJB) > Page 6720
C2280A (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Diagrams > Battery Junction Box (BJB) > Page 6721
C2280B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Diagrams > Battery Junction Box (BJB) > Page 6722
C2280C
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Diagrams > Battery Junction Box (BJB) > Page 6723
C2280D
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Diagrams > Battery Junction Box (BJB) > Page 6724
C2280E
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6727
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6728
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6729
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6730
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6731
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6732
Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6733
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6734
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6735
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6736
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6737
Relay Box: Application and ID Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Power Point, Rear
C474
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Power Point, Rear > Page 6743
C3063
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Power Point, Rear > Page 6744
C3064
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Power Point, Rear > Page 6745
C3323
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Page 6746
Auxiliary Power Outlet: Service and Repair
POWER POINT
Special Tool(s)
Special Tool(s)
Removal
NOTE: Power point cover may differ depending on location.
1. Open the power point cover. 2. Install the special tool in one of the power point socket slots.
3. Position the special tool so that it engages in the adjacent slot.
4. Using the special tool, pull the power point socket out of the retainer.
5. Disconnect the electrical connector.
Installation
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Page 6747
1. Connect the electrical connector. 2. Slide the power point socket into the retainer.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Diagrams > Ignition Transformer Capacitor 1
C174
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Diagrams > Ignition Transformer Capacitor 1 > Page 6752
C194
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Diagrams > Ignition Transformer Capacitor 1 > Page 6753
C1196
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6758
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6759
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6760
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6761
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6762
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6763
Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6764
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6765
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6766
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6767
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6768
Fuse: Locations Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6771
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6772
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6773
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6774
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6775
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6776
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6777
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6778
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6779
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6780
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6781
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6782
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6783
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6786
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6787
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6788
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6789
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6790
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6791
Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6792
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6793
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6794
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6795
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6796
Fuse: Application and ID Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6801
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6802
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6803
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6804
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6805
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6806
Fuse Block: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6807
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6808
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6809
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6810
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6811
Fuse Block: Locations Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6814
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6815
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6816
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6817
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6818
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6819
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6820
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6821
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6822
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6823
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6824
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6825
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6826
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6827
Fuse Block: Connector Views
C1035A
C1035B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6828
C2280A (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6829
C2280A (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6830
C2280B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6831
C2280C
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6832
C2280D
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6833
C2280E
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6836
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6837
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6838
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6839
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6840
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6841
Fuse Block: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6842
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6843
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6844
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6845
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6846
Fuse Block: Application and ID Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and
Inspection
Micro ISO Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and
Inspection
Mini ISO Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422
Multiple Junction Connector: Diagrams C110-C422
C110
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6857
C133
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6858
C134
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6859
C139
C140
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6860
C146
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6861
C192
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6862
C210 (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6863
C210 (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6864
C211
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6865
C212
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6866
C214 (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6867
C214 (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6868
C215
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6869
C219
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6870
C237
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6871
C248
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6872
C260
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6873
C300
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6874
C311 (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6875
C311 (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6876
C312 (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6877
C312 (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6878
C317
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6879
C327
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6880
C340
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6881
C313
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6882
C314
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6883
C315
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6884
C316
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6885
C328 (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6886
C328 (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6887
C339
C405
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6888
C406
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6889
C408
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6890
C410
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6891
C411
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6892
C421
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6893
C422
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6894
Multiple Junction Connector: Diagrams C423-C4004
C423
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6895
C431
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6896
C432
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6897
C438
C465
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6898
C494
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6899
C495
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6900
C510
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6901
C511
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6902
C610
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6903
C700
C800
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6904
C913
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6905
C925
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6906
C3007
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6907
C3047
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6908
C3049
C3050
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6909
C3052
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6910
C3053
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6911
C3134
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6912
C3135 (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6913
C3135 (Part 2)
C3138
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6914
C4000
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C422 > Page 6915
C4004
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service
and Repair
Power Distribution Module: Service and Repair
SMART JUNCTION BOX (SJB)
Special Tool(s)
Special Tool(s)
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service
and Repair > Page 6919
Part 2
Removal
CAUTION:
- If the SJB is dropped, damage to the internal components may occur. A new SJB must be
installed.
- Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage
may result.
NOTE:
- Prior to the replacement of the module, it is necessary to upload the module configuration
information into the appropriate scan tool. This information must be downloaded into the new
module after installation.
- The tire pressure monitoring system (TPMS) functionality is integral to the SJB.
- 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 a manufacturing mode with 6 pre-set DTCs related to the TPMS. To clear the DTCs, successful
configuration of the SJB must occur, followed by successful TPMS sensor training, and a
successful self-test, including clearing of the DTCs. The DTCs are as follows: B2477 (Module Configuration Failure)
- B2868 (Left Front Tire Pressure Sensor Fault)
- B2869 (Right Front Tire Pressure Sensor Fault)
- B2870 (Right Rear Tire Pressure Sensor Fault)
- B2871 (Left Rear Tire Pressure Sensor Fault)
- C2780 (ECU in Manufacturer Sub-State)
1. NOTE: This step is necessary only if the SJB is being replaced.
Upload the module configuration information from the SJB.
2. Remove the driver door scuff plate. 3. Position the LH door opening weather seal aside.
4. 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.
5. Remove the 2 bolts and the parking brake release handle. 6. Disconnect the parking brake
switch electrical connector. 7. Release the hood release cable pushpin from the parking brake
control bracket. 8. Release the harness clip from the parking brake cable housing.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service
and Repair > Page 6920
9. 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.
10. 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 (then lift it upward to disengage the lower tangs from the instrument panel),
disconnect the 2 electrical connectors and position the bezel assembly aside.
11 If necessary, push the LH instrument panel side finish panel out and position it aside.
12. Through the headlight switch bezel opening, remove the 2 SJB bolts. 13. From under the
instrument panel, remove the third (lower right) SJB bolt.
14. 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.
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 be present
in order 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 lower, right 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. 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.
12. Position the LH door opening weather seal.
13. NOTE: If the SJB was not replaced, this is the last step that is necessary.
Install the driver door scuff plate.
14. NOTE:
- When successful, this step provides the calibration necessary for the SJB operation and clears
DTC B2477. The clearing of this DTC indicates the calibration data has been successfully
downloaded to the new SJB.
- When successful, this step also programs the remote transmitters into the new SJB. In the event
the remote transmitters do not program to the new SJB, all of the remote transmitters will need to
be present and refer to Locks, Remote Keyless Entry Transmitter Programming. This action will
program the remote transmitters into the new SJB. See: Accessories and Optional
Equipment/Antitheft and Alarm Systems/Keyless Entry/Keyless Entry Transmitter/Testing and
Inspection/Remote Keyless Entry Transmitter Programming
Download the SJB configuration information from the scan tool into the new SJB.
15. 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service
and Repair > Page 6921
16. NOTE: DTC C2780 will not clear if any of the pre-set DTCs are still present in the SJB. When
successful, this step will clear the DTC C2780.
Carry out the SJB on-demand self-test by clearing DTCs, and then retrieving DTCs to confirm all
DTCs have been cleared.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro
ISO Relay > Component Information > Testing and Inspection
Micro ISO Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini
ISO Relay > Component Information > Testing and Inspection
Mini ISO Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
Distribution Module > Component Information > Service and Repair
Power Distribution Module: Service and Repair
SMART JUNCTION BOX (SJB)
Special Tool(s)
Special Tool(s)
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
Distribution Module > Component Information > Service and Repair > Page 6935
Part 2
Removal
CAUTION:
- If the SJB is dropped, damage to the internal components may occur. A new SJB must be
installed.
- Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage
may result.
NOTE:
- Prior to the replacement of the module, it is necessary to upload the module configuration
information into the appropriate scan tool. This information must be downloaded into the new
module after installation.
- The tire pressure monitoring system (TPMS) functionality is integral to the SJB.
- 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 a manufacturing mode with 6 pre-set DTCs related to the TPMS. To clear the DTCs, successful
configuration of the SJB must occur, followed by successful TPMS sensor training, and a
successful self-test, including clearing of the DTCs. The DTCs are as follows: B2477 (Module Configuration Failure)
- B2868 (Left Front Tire Pressure Sensor Fault)
- B2869 (Right Front Tire Pressure Sensor Fault)
- B2870 (Right Rear Tire Pressure Sensor Fault)
- B2871 (Left Rear Tire Pressure Sensor Fault)
- C2780 (ECU in Manufacturer Sub-State)
1. NOTE: This step is necessary only if the SJB is being replaced.
Upload the module configuration information from the SJB.
2. Remove the driver door scuff plate. 3. Position the LH door opening weather seal aside.
4. 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.
5. Remove the 2 bolts and the parking brake release handle. 6. Disconnect the parking brake
switch electrical connector. 7. Release the hood release cable pushpin from the parking brake
control bracket. 8. Release the harness clip from the parking brake cable housing.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
Distribution Module > Component Information > Service and Repair > Page 6936
9. 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.
10. 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 (then lift it upward to disengage the lower tangs from the instrument panel),
disconnect the 2 electrical connectors and position the bezel assembly aside.
11 If necessary, push the LH instrument panel side finish panel out and position it aside.
12. Through the headlight switch bezel opening, remove the 2 SJB bolts. 13. From under the
instrument panel, remove the third (lower right) SJB bolt.
14. 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.
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 be present
in order 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 lower, right 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. 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.
12. Position the LH door opening weather seal.
13. NOTE: If the SJB was not replaced, this is the last step that is necessary.
Install the driver door scuff plate.
14. NOTE:
- When successful, this step provides the calibration necessary for the SJB operation and clears
DTC B2477. The clearing of this DTC indicates the calibration data has been successfully
downloaded to the new SJB.
- When successful, this step also programs the remote transmitters into the new SJB. In the event
the remote transmitters do not program to the new SJB, all of the remote transmitters will need to
be present and refer to Locks, Remote Keyless Entry Transmitter Programming. This action will
program the remote transmitters into the new SJB. See: Accessories and Optional
Equipment/Antitheft and Alarm Systems/Keyless Entry/Keyless Entry Transmitter/Testing and
Inspection/Remote Keyless Entry Transmitter Programming
Download the SJB configuration information from the scan tool into the new SJB.
15. 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
Distribution Module > Component Information > Service and Repair > Page 6937
16. NOTE: DTC C2780 will not clear if any of the pre-set DTCs are still present in the SJB. When
successful, this step will clear the DTC C2780.
Carry out the SJB on-demand self-test by clearing DTCs, and then retrieving DTCs to confirm all
DTCs have been cleared.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6945
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6946
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6947
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6948
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6949
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6950
Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6951
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6952
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6953
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6954
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6955
Relay Box: Locations Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6958
Relay Box: Diagrams Smart Junction Box (SJB)
C2280A (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6959
C2280A (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6960
C2280B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6961
C2280C
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6962
C2280D
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6963
C2280E
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6966
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6967
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6968
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6969
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6970
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6971
Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6972
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6973
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6974
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6975
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 6976
Relay Box: Application and ID Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6981
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6982
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6983
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6984
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6985
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6986
Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6987
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6988
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6989
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6990
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6991
Relay Box: Locations Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery
Junction Box (BJB) > Page 6994
Relay Box: Diagrams Smart Junction Box (SJB)
C2280A (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery
Junction Box (BJB) > Page 6995
C2280A (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery
Junction Box (BJB) > Page 6996
C2280B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery
Junction Box (BJB) > Page 6997
C2280C
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery
Junction Box (BJB) > Page 6998
C2280D
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery
Junction Box (BJB) > Page 6999
C2280E
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 7002
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 7003
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 7004
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 7005
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 7006
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 7007
Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 7008
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 7009
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 7010
Fuse
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 7011
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 7012
Relay Box: Application and ID Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment
Specifications
Alignment: Specifications Alignment Specifications
Alignment Specifications
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment
Specifications > Page 7018
Alignment: Specifications General Specifications
General Specifications
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment
Specifications > Page 7019
Alignment: Specifications Torque Specifications
Torque Specifications
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 7020
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 flagnut with a non-flagnut 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 (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 7021
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.
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.
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 (V8-4.6L (2008))
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
following 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 lb-ft).
4. NOTE: 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 arm rearward nut.
6. Position the LF lower 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment - Front > Page 7024
Tighten the LF lower arm rearward nut to 200 Nm (148 lb-ft).
8. Recheck the camber and caster, adjust as necessary. 9. Check and, if necessary, adjust the
front toe.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment - Front > Page 7025
Alignment: Service and Repair Ride Height Measurement
Ride Height Measurement
Front Ride Height Measurement
Front Ride Height Measurement
NOTE: Make sure that the vehicle is positioned on a flat, level surface and the tires are inflated to
the correct pressure. Vehicle should have a full tank of fuel.
1. Position a suitable surface gauge (such as Starrett 57D Surface Gauge), on a flat, level surface
and adjust the gauge's arm until the scriber point is
located in the center of the lower arm inboard bolt. ^
Lock the surface gauge in this position.
2. With the surface gauge positioned on a flat, level surface, record the measurement of the
surface gauge position (measurement A).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment - Front > Page 7026
3. Position the surface gauge on the same flat, level surface as used in Step 1, adjust the gauge's
arm until the scriber point is located in the center of
the shock absorber lower bolt. ^
Lock the surface gauge in this position.
4. With the surface gauge positioned on a flat, level surface, record the measurement of the
surface gauge position (measurement B).
5. Subtract measurement B from measurement A to obtain the front ride height.
^ Refer to Specifications.
Rear Ride Height Measurement
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment - Front > Page 7027
Rear Ride Height Measurement
NOTE: Make sure that the vehicle is positioned on a flat, level surface and the tires are inflated to
the correct pressure. Vehicle should have a full tank of fuel.
1. Measure the distance between the flat level surface and the center of the lower arm inboard bolt
(measurement A). 2. Measure the distance between the flat level surface and the center of the
shock absorber lower bolt (measurement B). 3. Subtract measurement B from measurement A to
obtain the rear ride height.
^ Refer to Specifications.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment - Front > Page 7028
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.
6. Rotate the front wheel inner tie rods until the toe setting is within specification.
7. 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 lb-ft).
8. Install the clamps. 9. Recheck the toe settings and adjust if necessary.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment - Front > Page 7029
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 lb-ft).
7. Recheck the toe settings and adjust if necessary.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment - Front > Page 7030
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 flagnut must be removed and replaced with a non-flagnut 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.
3. Using alignment equipment and the manufacturer's instructions, measure the rear camber.
4. 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.
5. NOTE: Make sure that the camber settings are not disturbed while tightening the nut.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment - Front > Page 7031
Tighten the upper arm inboard nut to 250 Nm (185 lb-ft).
6. Recheck the camber settings and adjust as necessary. 7. Check and, if necessary, adjust the
rear toe.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 7037
C121
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 7038
Power Steering Pressure Switch: Description and Operation
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.
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 (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Locations
Steering Angle Sensor: Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 7042
View 151-15
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 7043
C226
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Locations
Steering Angle Sensor: Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 7048
View 151-15
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 7049
C226
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Monitoring System (TPMS) Sensor Training
Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor
Training
Tire Pressure Monitoring System (TPMS) Sensor Training
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). For additional information, refer to
Tire Pressure Monitoring System (TPMS) Sensor Activation.
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 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 activation tool, attempt to activate the same sensor with
the activation tool. If the sensor still does not respond, move the vehicle to rotate the wheels at
least 1/4 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. NOTE: 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.
6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the
activation tool must remain in place 180 degrees from
the valve stem.
Place the activation tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press
and release the test button on the special tool. The horn will sound briefly to indicate that the tire
pressure sensor has been recognized by the SJB.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Monitoring System (TPMS) Sensor Training > Page 7055
7. Within 2 minutes of the horn sounding, place the 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.
8. 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.
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 IDs trained to the SJB and document them
on the applicable warranty claim.
10. 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.
If the sensors are being trained due to the installation of a new SJB, clear any DTCs and perform
the SJB on-demand self test.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Monitoring System (TPMS) Sensor Training > Page 7056
Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor
Activation
Tire Pressure Monitoring System (TPMS) Sensor Activation
NOTE: The tire pressure sensors will go into a "sleep mode" after 30 minutes of inactivity to
conserve battery power. The sensors do not transmit information while in sleep mode, it will be
necessary to wake them up so they will transmit the latest tire pressure information.
1. Turn the ignition switch to the ON position. 2. Position the tire pressure monitor activation tool
against the LF tire sidewall 180 degrees from the tire valve stem.
3. NOTE: The activation tool will provide feedback in the form of a flashing green light and a beep
sound for each successful response from a tire
pressure sensor.
Press the test button on the activation tool to activate the sensor, activate the sensor at least 2
times.
4. Repeat Steps 2 and 3 for the remaining tires. 5. If the tire pressure monitoring system (TPMS)
indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom
Chart
in Diagnosis and Testing.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Disassembly
WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous
chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes,
flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any
part of the battery is swallowed, contact a physician immediately. When disposing of TPMS
sensors, follow the correct procedures for hazardous material disposal. Failure to follow these
instructions may result in serious personal injury.
NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of
accordingly.
NOTE: 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.
1. CAUTION: The sensor, cradle and strap may 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 may occur.
Using a pocket screwdriver or similar tool, remove the sensor locking clip.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7059
3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to
the sensor may 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 may 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 (V8-4.6L (2008))
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 7060
3. CAUTION: The sensor, cradle and strap may 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 (V8-4.6L (2008))
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 7061
Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and
Cradle
Tire Pressure Monitoring System (TPMS) Strap and Cradle
Disassembly
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7062
WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous
chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes,
flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any
part of the battery is swallowed, contact a physician immediately. When disposing of TPMS
sensors, follow the correct procedures for hazardous material disposal. Failure to follow these
instructions may result in serious personal injury.
NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of
accordingly.
NOTE: 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.
1. Remove the tire pressure monitoring system (TPMS) sensor. For additional information, refer to
Tire Pressure Monitoring System (TPMS) Sensor.
2. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this
instruction may result in serious personal injury.
WARNING: Wear protective gloves when handling components or parts that have pointed or sharp
edges. Failure to follow this instruction may result in serious personal injury.
Remove a factory installed strap in the following 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.
3. To remove a dealer installed strap, turn the worm gear screw until the strap is fully released from
the worm gear.
^ Discard the strap.
4. 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 may 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 (V8-4.6L (2008))
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 7063
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 degrees 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 and
sensor are mounted at the lowest spot
possible to avoid damaging the sensor during wheel and tire disassembly and assembly.
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 lb-inch).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7064
6. CAUTION: The sensor, cradle and strap may 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 (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair
Front Steering Knuckle: Service and Repair
Wheel Knuckle
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Page 7069
Removal and Installation
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure may result in major service expense. New parts must be
installed with the same part numbers or equivalent part, if replacement is 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 and tire.
2. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or
damage to the hose can occur.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Page 7070
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 lb-ft).
3. Remove the brake disc 4. Disconnect the wheel speed sensor harness pin-type retainers. 5.
Disconnect the wheel speed sensor electrical connector. 6. Remove the wheel speed sensor
harness bracket bolt from the wheel knuckle.
^ To install, tighten to 8 Nm (71 lb-inch).
7. Remove and discard the tie-rod end nut.
^ To install, tighten to 103 Nm (76 lb-ft).
8. 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.
9. Remove and discard the lower ball joint nut.
^ To install, tighten to 150 Nm (111 lb-ft).
10. 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.
11. Remove and discard the upper ball joint nut.
^ To install, tighten to 55 Nm (41 lb-ft).
12. 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Page 7071
13. To install, reverse the removal procedure.
^ Check and, if necessary, align the front end.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
CAUTION: If the air is not purged from the power steering system correctly, premature power
steering pump failure may result. The condition may 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. Refer to the appropriate procedure. 3. Tightly insert the
stopper of the vacuum pump into the reservoir. 4. Start the engine. 5. Install the vacuum pump,
apply vacuum and maintain the maximum vacuum of 68-85 kPa (20-25 in-Hg). 6. If equipped with
Hydro-Boost(R), apply the brake pedal twice.
7. CAUTION: Do not hold the steering wheel against the stops for an extended amount of time.
Damage to the power steering pump may
occur.
Cycle the steering wheel fully from stop-to-stop 10 times.
8. Stop the engine. 9. Release the vacuum and remove the vacuum pump.
10. NOTE: Do not overfill the reservoir. Fill the reservoir.
^ Use approved transmission fluid.
11. Start the engine. 12. Install the vacuum pump. Apply and maintain the maximum vacuum of
68-85 kPa (20-25 in-Hg).
13. CAUTION: Do not hold the steering wheel against the stops for an extended amount of time.
Damage to the power steering pump may
occur.
Cycle the steering wheel fully from stop-to-stop 10 times.
14. Stop the engine, release the vacuum and remove the vacuum pump.
15. NOTE: Do not overfill the reservoir.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System
Information > Service and Repair > Page 7076
Fill the reservoir as needed and install the reservoir cap.
16. Visually inspect the power steering system for leaks.
17. NOTE: 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 (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Specifications
Power Steering Fluid: Specifications
Power Steering Fluid Type
Ford Part Name ...................................................................................................................................
................................ Motorcraft MERCON V ATF Ford Part Number .................................................
............................................................................................................................................. XT-5-QM
Ford Specification ................................................................................................................................
......................................................... MERCON V
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Specifications > Page 7080
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.
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 an extended amount of time. Damage
to the power steering pump may 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 1.89L (2 qt) of power
steering fluid.
10. CAUTION: Do not hold the steering wheel at the stops for an extended amount of time.
Damage to the power steering pump may 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. Using the special tool (UV lamp), inspect the system for traces of UV dye. Repair as necessary.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Service and Repair > Page 7084
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Service and Repair > Page 7085
Removal and Installation
CAUTION: While repairing the power steering system, care should be taken to prevent the entry of
foreign material or failure of the power steering components may result.
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Release the power steering fluid cooler
clamp and disconnect the fluid cooler 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 power steering fluid cooler hose braces. 6. Remove the power steering fluid
cooler hose bracket bolt.
^ To install, tighten to 18 Nm (13 lb-ft).
7. Remove the steering line clamp plate nut.
^ To install, tighten to 25 Nm (18 lb-ft).
8. Rotate the steering line clamp plate and disconnect the power steering fluid cooler 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 power steering pressure and fluid
cooler line is disconnected from the steering gear.
To install, reverse the removal procedure. ^
Fill the power steering system.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir >
Component Information > Service and Repair > Page 7089
Removal and Installation
CAUTION: While repairing the power steering system, care should be taken to prevent the entry of
foreign material or failure of the power steering components may result.
1. Using a suitable suction device, remove the power steering fluid from the reservoir. 2. Remove
the power steering fluid reservoir bolt.
^ To install, tighten to 9 Nm (80 lb-inch).
3. Release the power steering pump supply hose clamp and disconnect the hose. 4. Release the
power steering fluid cooler 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 (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair > Page 7093
Removal
CAUTION: While repairing the power steering system, care should be taken to prevent the entry of
foreign material or failure of the power steering components may result.
1. With the vehicle in NEUTRAL, position it on a hoist. 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 power steering fluid cooler from the steering gear.
^ Discard the O-ring seal.
5. Disconnect the pressure line from the steering gear.
^ Discard the O-ring seal.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair > Page 7094
6. Remove the pressure line bracket-to-engine nut (4.6L) or bolt (4.0L). 7. Remove the pressure
line bracket-to-crossmember bolt. 8. Disconnect the pressure line-to-pump fitting.
^ Remove and discard the Teflon(R) seal.
9. Remove the pressure line.
Installation
1. NOTE: new Teflon(R) seal must be installed.
Using the special tool, install a new Teflon(R) seal on the pressure line fitting.
2. Position the pressure line and connect the pressure line-to-pump fitting.
^ Tighten to 65 Nm (48 lb-ft).
3. Install the pressure line bracket-to-engine nut (4.6L) or bolt (4.0L).
^ Tighten to 11 Nm (8 lb-ft).
4. NOTE: New O-rings must be installed whenever the pressure line and fluid cooler are
disconnected from the steering gear.
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 lb-ft).
6. Install a new O-ring seal and position the power steering fluid cooler 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 lb-ft).
8. Install the power steering pump pulley. 9. Fill the power steering system.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 - 4.6L
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump > Page 7099
Removal and Installation
CAUTION: While repairing the power steering system, care should be taken to prevent the entry of
foreign material or failure of the power steering components may result.
1. Using a suitable suction device, remove the power steering fluid from the reservoir. 2. With the
vehicle in NEUTRAL, position it on a hoist. 3. Remove the power steering pump pulley. 4. Remove
the pressure line bracket-to-engine nut.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump > Page 7100
5. Compress the clamp and disconnect the power steering pump supply hose. 6. Disconnect the
pressure line-to-pump fitting.
^ Remove and discard the Teflon(R) seal.
7. Remove the 2 engine wiring bracket nuts and position the wiring harness and ground cable
aside.
8. Remove the 3 bolts and the power steering pump.
Installation
1. NOTE: new Teflon(R) seal must be installed.
Using the special tool, install a new Teflon(R) seal on the pressure line-to-pump fitting.
2. Position the power steering pump and install the 3 bolts.
^ To install, tighten to 20 Nm (15 lb-ft).
3. Position the ground cable and engine wiring bracket. Install the 2 nuts.
^ Tighten to 20 Nm (15 lb-ft).
4. Connect the pressure line-to-pump fitting.
^ Tighten to 65 Nm (48 lb-ft).
5. Connect the power steering pump supply hose. 6. Install the pressure line bracket-to-engine nut.
^ Tighten to 11 Nm (8 lb-ft).
7. Install the power steering pump pulley. 8. Fill the power steering system.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump > Page 7101
Power Steering Pump: Service and Repair Power Steering Pump Pulley
Power Steering Pump Pulley - 4.6L
Removal
1. Remove the engine air cleaner outlet pipe. 2. Rotate the tensioner and remove the engine
accessory drive belt from the power steering pump pulley. 3. Using the special tool, remove the
pulley.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump > Page 7102
Installation
1. CAUTION: Do not install a power steering pump pulley that has been removed and installed
twice or pulley failure and/or pump damage
may occur. Inspect the pulley for paint marks in the web area near the hub. If there are 2 paint
marks, discard the pulley and install a new one. If there is 1 paint mark or no paint marks, use a
paint pencil to mark the web area of the pulley near the hub.
Using the special tool, install the pulley.
2. Rotate the tensioner and install the engine accessory drive belt on the power steering pump
pulley. 3. Install the engine air cleaner outlet pipe.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering
Pressure Switch > Component Information > Locations
View 151-2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering
Pressure Switch > Component Information > Locations > Page 7107
C121
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering
Pressure Switch > Component Information > Locations > Page 7108
Power Steering Pressure Switch: Description and Operation
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.
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 (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor
> Component Information > Locations
Steering Angle Sensor: Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor
> Component Information > Locations > Page 7112
View 151-15
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor
> Component Information > Locations > Page 7113
C226
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information >
Locations
Steering Angle Sensor: Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information >
Locations > Page 7117
View 151-15
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information >
Locations > Page 7118
C226
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 eye protection when servicing a vehicle. Failure to follow this instruction may result in
serious personal injury.
- Never probe the electrical connectors on air bag, safety canopy or side air curtain modules.
Failure to follow this instruction may result in the accidental deployment of these modules, which
increases the risk of serious personal injury or death.
- 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 this
instruction may result in the accidental deployment of the safety canopy and cause serious
personal injury or death.
- To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to
follow this instruction may result in serious personal injury or death.
NOTE: The air bag warning indicator 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.
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 warning indicator for at least 30 seconds.
The air bag warning indicator will remain lit
continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning
indicator does not remain lit continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition switch to OFF.
6. WARNING: Always deplete the backup power supply before repairing or installing any new front
or side air bag supplemental restraint
system (SRS) component and before servicing, removing, installing, adjusting or striking
components near the front or side impact sensors or the restraints control module (RCM). Nearby
components include doors, instrument panel, console, door latches, strikers, seats and hood
latches.
Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and
impact sensor(s).
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Failure to follow these instructions may result in serious personal injury or death in the event of an
accidental deployment.
Disconnect the battery ground cable and wait at least one minute.
Repowering Procedure
1. Turn the ignition switch from OFF to ON. 2. Install RCM fuse 17 (10A) to the SJB and close the
cover.
3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of
any air bag module when the battery is
connected. Failure to follow these instructions may result in serious personal injury in the event of
an accidental deployment. Connect the
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
7124
battery ground cable.
Connect the battery ground cable.
4. 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 warning indicator with the air bag modules installed. The air bag
warning indicator will light continuously for approximately 6 seconds and then turn off. If an SRS
fault is present, the air bag warning indicator will: fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag warning 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 warning 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 warning
indicator and any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the RCM and occupant classification system module (OCSM)
using a scan tool.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
7125
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 eye protection when servicing a vehicle. Failure to follow this instruction may result in
serious personal injury.
- Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear
seam pointed away from the body. Do not set a live air bag module down with the deployment
door/trim cover/tear seam face down. Failure to follow these instructions may result in serious
personal injury in the event of an accidental deployment.
- Never probe the electrical connectors on air bag, safety canopy or side air curtain modules.
Failure to follow this instruction may result in the accidental deployment of these modules, which
increases the risk of serious personal injury or death.
- Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive
load limiting retractors. Failure to follow this instruction may result in the accidental deployment of
the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious
personal injury or death.
- 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.
- To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to
follow this instruction may result in serious personal injury or death.
NOTE: The air bag warning indicator 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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
7126
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 warning indicator for at least 30 seconds.
The air bag warning indicator will remain lit
continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning
indicator does not remain lit continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: Always deplete the backup power supply before repairing or installing any new front
or side air bag supplemental restraint
system (SRS) component and before servicing, removing, installing, adjusting or striking
components near the front or side impact sensors or the restraints control module (RCM). Nearby
components include doors, instrument panel, console, door latches, strikers, seats and hood
latches.
Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and
impact sensor(s).
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Failure to follow these instructions may result in serious personal injury or death in the event of an
accidental deployment.
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.
9. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
7127
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.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
7128
15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat
side air bag module electrical connector.
Explorer and Mountaineer vehicles 16. Release and position aside the passenger side C-pillar trim
panel.
17. Disconnect the passenger side safety canopy module electrical connector.
18. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy module electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
7129
19. Release and position aside the driver side C-pillar trim panel.
20. Disconnect the driver side safety canopy module electrical connector.
21. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy module electrical connector.
Explorer Sport Trac vehicles 22. Remove the driver and passenger side upper C-pillar trim panels.
23. Disconnect the passenger side safety canopy module electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
7130
24. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy module electrical connector.
25. Disconnect the driver side safety canopy module electrical connector.
26. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy module electrical connector.
All vehicles 27. 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
7131
28. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air
bag module electrical connector.
29. Install the RCM fuse 17 (10A) to the SJB. 30. 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. 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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
7132
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.
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 10. Remove the restraint system diagnostic tool from the
vehicle harness side of the driver side safety canopy module electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
7133
11. Connect the driver side safety canopy module electrical connector.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
7134
15. Install the passenger side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
All vehicles 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
7135
19. Connect the LH side passenger air bag module electrical connector.
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 driver air bag module electrical connectors are unique and cannot be reversed
when connected to 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. Damage to the connector or component
may occur.
Connect the driver air bag module electrical connectors as noted in removal.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
7136
24. Install the 2 driver air bag module bolts (1 shown).
- Tighten to 7 Nm (62 lb-in).
25. 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.
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: Make sure no one is in the vehicle and there is nothing blocking or placed in front
of any air bag module when the battery is
connected. Failure to follow these instructions may result in serious personal injury in the event of
an accidental deployment.
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 warning indicator with the air bag modules installed. The air bag
warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag
SRS fault is present, the air bag warning indicator will: fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag warning 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 warning 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 warning
indicator and any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the RCM and occupant classification system module (OCSM)
using a scan tool.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Adaptive Collapsible Steering Column
> Component Information > Service and Repair
Adaptive Collapsible Steering Column: Service and Repair
DEPLOYABLE STEERING COLUMN - IN-VEHICLE DEPLOYMENT
WARNING: Deploy all supplemental restraint system (SRS) devices (air bags, pretensioners, load
limiters, etc.) outdoors with all personnel at least 9.14 meters (30 feet) away to make sure of
personal safety. Due to the loud report which occurs when an SRS device is deployed, hearing
protection is required. Failure to follow these instructions may result in serious personal injury.
1. Depower the SRS.
2. NOTE: It may be necessary to lower or remove the deployable steering column from the
instrument panel to access the deployable steering
column electrical connector.
Access the deployable steering column electrical connector.
3. NOTE: If the deployable steering column does not have a hard-wired pigtail, it will be necessary
to cut the wires and connector(s) from the
vehicle wire harness and reconnect to the deployable steering column.
Cut each of the deployable steering column wires, leaving at least 4 inches to work with.
4. Remove any sheathing (if present) and strip the insulation from the ends of the cut wires. 5.
Make a jumper harness to deploy the deployable steering column.
- Obtain 2 wires (20 gauge minimum) at least 9.14 m (30 ft) long and strip both ends of each wire.
- At one end of the jumper harness, connect the wires together.
6. Using the end of the jumper harness that the wires are not connected together, attach each wire
of the jumper harness to each wire of the
deployable steering column. Use tape or other insulating material to make sure that the leads do
not make contact with each other.
7. Remain at least 9.14 m (30 ft) away from the deployable steering column. 8. From the end of the
jumper harness that is not connected to the deployable steering column, disconnect the 2 wires of
the jumper harness from
each other.
9. Deploy the deployable steering column by touching the ends of the 2 wires of the jumper
harness to the terminals of a 12-volt battery.
10. To allow for cooling, wait at least 10 minutes before approaching the deployed steering column.
11. Dispose of the deployed steering column in the same manner as any other part to be scrapped.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and
Inspection > Steering Gear Valve Test
Steering Gear: Testing and Inspection Steering Gear Valve Test
Steering Gear Valve Test
1. With the vehicle in motion, place the transmission in NEUTRAL and turn the engine OFF.
^ If the vehicle does not pull with the engine OFF, repair or install a new steering gear.
2. If the vehicle pulls with the engine OFF, switch the right side front wheel to the left side of the
vehicle and the left side front wheel to the right side
of the vehicle.
3. If the vehicle pulls to the opposite side, switch the front wheels with the rear wheels keeping
them on the same side of the vehicle. 4. If the vehicle pull direction does not change, check the
front suspension components, wheel alignment and frame alignment.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and
Inspection > Steering Gear Valve Test > Page 7144
Steering Gear: Testing and Inspection Steering Gear Grunt/Shudder Test
Steering Gear Grunt/Shudder Test
1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1,200 rpm.
3. CAUTION: Do not hold the steering wheel against the stops for an extended amount of time.
Damage to the power steering pump may
occur.
Rotate the steering wheel to the RH stop, then turn the steering wheel 90 degrees back from that
position. Slowly turn the steering wheel back and forth approximately 1/12 of a full turn.
4. Turn the steering wheel another 90 degrees. Slowly turn the steering wheel back and forth
approximately 1/12 of a full turn. 5. Repeat the test with the power steering fluid at different
temperatures. 6. If a light grunt is heard or a low (50-200 Hz) shudder is present, this is a normal
steering system condition. 7. If a loud grunt is heard, or a strong shudder is felt, purge the power
steering system. Refer to Power Steering System Purging. If a loud grunt or
strong shudder still exists, check the power steering lines/hoses for restrictions or damage and
repair as necessary. If the lines/hoses are OK, install a new steering gear.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and
Inspection > Page 7145
Steering Gear: Service and Repair
Steering Gear
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and
Inspection > Page 7146
Removal and Installation
All vehicles
CAUTION: While repairing the power steering system, care should be taken to prevent the entry of
foreign material or failure of the power steering components may result.
1. CAUTION: Do not allow the steering column to rotate while the steering column shaft is
disconnected or damage to the clockspring may
result. If there is evidence that the lower shaft has rotated, the clockspring must be removed and
recentered.
Hold the steering wheel in the straight-ahead position using a suitable device.
2. Remove the front tires and wheels. 3. If equipped, remove the 2 bolts, pin-type retainer and the
oil shield.
^ To install, tighten to 15 Nm (11 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and
Inspection > Page 7147
4. NOTE: Install a new lower steering column shaft-to-steering gear bolt.
Remove and discard the lower steering column shaft-to-steering gear bolt. ^
To install, tighten to 48 Nm (35 lb-ft).
5. Disconnect the lower steering column shaft from the steering gear. 6. Remove the steering line
clamp plate nut.
^ To install, tighten to 25 Nm (18 lb-ft).
7. Rotate the steering line clamp plate and disconnect the power steering pressure line and fluid
cooler.
8. NOTE: New O-rings must be installed whenever the power steering line and fluid cooler are
disconnected from the steering gear.
Remove and discard the 2 O-rings.
9. NOTE: New tie-rod end nuts must be installed.
Remove and discard the 2 tie-rod end nuts. ^
To install, tighten to 103 Nm (76 lb-ft).
10. CAUTION: Do not damage the tie-rod end boot when installing the special tool.
Using the special tool, separate the 2 tie-rod ends from the wheel knuckle.
11. Remove the 2 steering gear-to-crossmember nuts and bolts.
^ To install, tighten to 350 Nm (258 lb-ft).
Four wheel drive (4WD) vehicles
NOTE: On four wheel drive (4WD) vehicles, the following steps (LH lower arm only) must be
carried out to provide clearance to remove the steering gear.
12. Remove the shock absorber lower bolt and flagnut.
^ Discard the flagnut.
^ To install, tighten to 350 Nm (258 lb-ft).
13. CAUTION: Do not tighten the LH lower arm nuts and bolts until the installation procedure is
complete and the weight of the vehicle is
resting on the wheel and tire assemblies or incorrect clamp load or bushing damage may occur.
NOTE: It is not necessary to disconnect the LH lower ball joint.
Remove and discard the lower arm forward bolt and nut and the lower arm rearward flag bolt and
nut. ^
To install the lower arm forward bolt, tighten to 400 Nm (296 lb-ft).
^ To install the lower arm rearward flag bolt and nut, tighten to 200 Nm (148 lb-ft).
14. Remove the stabilizer bar link nut and the link.
^ Discard the stabilizer bar link nut.
^ To install, tighten to 35 Nm (26 lb-ft).
All vehicles
15. Remove the steering gear from the LH side of the vehicle. 16. If a new steering gear is being
installed, remove the 4 steering gear bushings and the 2 nuts.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Testing and
Inspection > Page 7148
17. CAUTION: On four wheel drive (4WD) vehicles, do not tighten the LH lower arm nuts and bolts
until the installation procedure is
complete and the weight of the vehicle is resting on the wheel and tire assemblies or incorrect
clamp load bushing damage may occur.
To install, reverse the removal procedure. ^
Install 2 new O-ring seals.
^ Fill the power steering system.
^ Check and, if necessary, set the front toe.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 to rotate while the steering column shaft is
disconnected or damage to the clockspring may
result. If there is evidence that the shaft has rotated, the clockspring must be removed and
recentered.
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. WARNING: Install a new steering column shaft bolt. Reuse could result in bolt failure and loss of
vehicle control. Failure to follow this
instruction may result in serious injury to vehicle occupant(s).
Remove and discard the upper steering column shaft-to-steering column bolt. ^
To install, tighten to 30 Nm (22 lb-ft).
3. Remove the 3 upper steering column shaft dash seal bolts.
^ To install, tighten to 12 Nm (9 lb-ft).
4. WARNING: Install a new steering column shaft bolt. Reuse could result in bolt failure and loss of
vehicle control. Failure to follow this
instruction may result in serious injury to vehicle occupant(s).
Remove and discard the lower steering column shaft-to-upper steering column shaft bolt. ^
To install, tighten to 47 Nm (35 lb-ft).
5. Remove the upper steering column shaft. 6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and
Repair > Steering Column Shaft - Upper > Page 7153
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.
2. CAUTION: Do not allow the steering column shaft to rotate while the steering column 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.
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. WARNING: Install a new steering column shaft bolt. Reuse could result in bolt failure and loss of
vehicle control. Failure to follow this
instruction may result in serious injury to vehicle occupant(s).
Remove and discard the lower steering column shaft-to-upper steering column shaft bolt. ^
To install, tighten to 47 Nm (35 lb-ft).
4. WARNING: Install a new steering column shaft bolt. Reuse could result in bolt failure and loss of
vehicle control. Failure to follow this
instruction may result in serious injury to vehicle occupant(s).
Remove and discard the lower steering column shaft-to-steering gear bolt. ^
To install, tighten to 47 Nm (35 lb-ft).
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. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Locations
View 151-16
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Locations >
Page 7157
C203
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Locations >
Page 7158
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. 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 lb-ft).
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair
Tie Rod: Service and Repair
Inner Tie Rod
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair >
Page 7162
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 damage. 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 foreign material 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. Incorrect venting may lead to internal component damage.
1. Remove the front tire and wheel. 2. Loosen the tie-rod end jam nut. 3. Remove and discard the
tie-rod end nut.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair >
Page 7163
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: new outer bellows boot clamp must be installed.
Using the boot clamp pliers, remove and discard the outer bellows boot clamp.
8. NOTE: new inner bellows boot clamp must be installed.
Using the boot clamp pliers, 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 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair >
Page 7164
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.
3. Using the special tool, install a new inner bellows boot clamp.
4. 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.
5. Thread the tie-rod end jam nut onto the inner tie rod.
6. 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.
7. Tighten the tie-rod end jam nut.
^ Tighten to 80 Nm (59 lb-ft).
8. Position the tie-rod end to the wheel knuckle and install a new tie-rod end nut.
^ Tighten to 103 Nm (76 lb-ft).
9. Check and, if necessary, align the front end.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 in) Upper ...................................................................
........................................................................................................................... 0-0.2 mm (0-0.008
in)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications >
Page 7169
Ball Joint: Testing and Inspection
Ball Joint Inspection
1. Prior to inspecting the ball joints for wear, inspect the wheel bearings. Refer to Vehicle/Testing
and inspection.
2. NOTE: In order to obtain accurate measurements, 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. Suspension damage may 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. Suspension damage may 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications >
Page 7170
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. ^
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.
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.
^ If the deflection meets the specification, no further action is required.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 7175
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 7176
Removal
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure may result in major service expense. New parts must be
installed with the same part numbers or equivalent part, if replacement is 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. 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 the wheel and tire. 3. Remove and discard the lower ball joint nut.
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 and grommet. 6. Remove the stabilizer bar link.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 7177
7. Remove and discard the shock absorber lower bolt and flag nut. 8. Remove and discard the
lower arm forward nut and bolt. 9. Remove the lower arm rearward nut and bolt and the lower
control arm.
^ Discard the nut and bolt.
Installation
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). This will prevent incorrect clamp load and bushing
damage.
1. NOTE: Do not tighten the bolt at this time.
Position the lower arm and install the lower arm rearward bolt and nut.
2. NOTE: Do not tighten the bolt at this time.
Install the lower arm forward bolt and nut.
3. NOTE: Do not tighten the bolt at this time.
Install the shock absorber lower bolt and flag nut.
4. Install the stabilizer bar link.
^ Tighten the nut to 35 Nm (26 lb-ft).
5. Connect the lower ball joint to the wheel knuckle and install the lower ball joint nut.
^ Tighten to 150 Nm (111 lb-ft).
6. Using a suitable jack, 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).
7. Tighten the shock absorber lower bolt to 350 Nm (258 lb-ft). 8. Tighten the lower arm forward nut
to 400 Nm (296 lb-ft). 9. Tighten the lower arm rearward nut to 200 Nm (148 lb-ft).
10. Install the wheel and tire. 11. Check and if necessary, align the front end.
Upper Arm
Upper Arm
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 7178
Removal
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure may result in major service expense. New parts must be
installed with the same part numbers or equivalent part, if replacement is 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. 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 the wheel and tire. 3. Using a suitable jack support the lower control arm near the lower
ball joint. 4. Remove and discard the upper ball joint nut.
5. CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to
the wheel knuckle can result.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 7179
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 and discard the 2 upper arm bolts and flag nuts and the upper arm.
Installation
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). This will prevent incorrect clamp load and bushing
damage.
1. NOTE: Do not tighten the bolt at this time.
Position the upper arm and install the 2 upper arm bolts and flag nuts.
2. Remove the plastic tie strap. 3. Connect the upper ball joint to the wheel knuckle and install the
upper ball joint nut.
^ Tighten to 55 Nm (41 lb-ft).
4. Using a suitable jack, 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).
5. Tighten the 2 upper arm bolts to 150 Nm (111 lb-ft). 6. Install the wheel and tire. 7. Check and if
necessary, align the front end.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 7180
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
components and systems and their failure may result in major service expense. New parts must be
installed with the same part numbers or equivalent part, if replacement is 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, or incorrect clamp load and
component damage may occur.
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 (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 7181
2. Remove the wheel and tire. 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 flagnut. This flagnut is used to
set and maintain the rear camber settings.
Discard the flagnut and install a non-flagnut to allow the rear camber to be adjusted.
Remove and discard the upper arm inboard bolt and flagnut and remove the upper arm.
Installation
1. Position the upper arm and install a new inboard bolt and non-flagnut.
^ Tighten to 250 Nm (185 lb-ft).
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 225 Nm (166 lb-ft).
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 (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 7182
Lower Arm
Removal
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure may result in major service expense. New parts must be
installed with the same part numbers or equivalent part, if replacement is 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 or incorrect clamp load and
component damage may occur.
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 (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 7183
2. Remove the wheel and tire. 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 flagnut. 5. Remove the stabilizer bar link
nut and grommet and the stabilizer bar link.
^ 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. NOTE: 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. NOTE: 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 and a new nut and grommet.
^ Tighten to 30 Nm (22 lb-ft).
5. Install a new lower arm outboard bolt and flagnut.
^ Tighten the bolt to 275 Nm (203 lb-ft).
6. Tighten the lower arm inboard bolt to 250 Nm (185 lb-ft). 7. Tighten the shock absorber lower
bolt to 275 Nm (203 lb-ft). 8. Lower the suspension and remove the jack. 9. Install the wheel and
tire.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information >
Specifications
Cross-Member: Specifications
Torque Specifications
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service
and Repair > Transmission Support Crossmember
Cross-Member: Service and Repair Transmission Support Crossmember
Transmission Support Crossmember
Transmission Support Crossmember
Removal and Installation
1. With the vehicle in NEUTRAL, position it on 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).
3. NOTE: Explorer/Mountaineer shown, Explorer Sport Trac similar.
Remove the heat shield bolt from the RH heat shield.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service
and Repair > Transmission Support Crossmember > Page 7189
- 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 (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service
and Repair > Transmission Support Crossmember > Page 7190
Cross-Member: Service and Repair Crossmember - 1B
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 (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair
Front Steering Knuckle: Service and Repair
Wheel Knuckle
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Page 7194
Removal and Installation
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure may result in major service expense. New parts must be
installed with the same part numbers or equivalent part, if replacement is 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 and tire.
2. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or
damage to the hose can occur.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Page 7195
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 lb-ft).
3. Remove the brake disc 4. Disconnect the wheel speed sensor harness pin-type retainers. 5.
Disconnect the wheel speed sensor electrical connector. 6. Remove the wheel speed sensor
harness bracket bolt from the wheel knuckle.
^ To install, tighten to 8 Nm (71 lb-inch).
7. Remove and discard the tie-rod end nut.
^ To install, tighten to 103 Nm (76 lb-ft).
8. 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.
9. Remove and discard the lower ball joint nut.
^ To install, tighten to 150 Nm (111 lb-ft).
10. 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.
11. Remove and discard the upper ball joint nut.
^ To install, tighten to 55 Nm (41 lb-ft).
12. 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Page 7196
13. To install, reverse the removal procedure.
^ Check and, if necessary, align the front end.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and
Repair
Rear Knuckle: Service and Repair
Wheel Knuckle
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and
Repair > Page 7200
Removal
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure may result in major service expense. New parts must be
installed with the same part numbers or equivalent part, if replacement is 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 or incorrect clamp load and damage
to components may occur.
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 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 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 may result.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and
Repair > Page 7201
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 lb-ft).
2. Install a new lower arm outboard bolt and flagnut.
^ Tighten to 275 Nm (203 lb-ft).
3. CAUTION: The upper arm outboard bolt must be installed with the bolt head toward the front of
the vehicle or wheel damage may
occur.
Install a new upper arm outboard bolt and nut with the bolt head toward the front of the vehicle. ^
Tighten to 225 Nm (166 lb-ft).
4. Position the toe link and install a new toe link outboard bolt and nut.
^ Tighten to 325 Nm (240 lb-ft).
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 lb-inch).
8. Using a suitable halfshaft installer tool, install the halfshaft.
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 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
components and systems and their failure may result in major service expense. New parts must be
installed with the same part numbers or equivalent part, if replacement is 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 or incorrect clamp load and
component damage may occur.
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 (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle Alignment Link > Component
Information > Service and Repair > Page 7205
2. Remove the wheel and tire. 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 325 Nm (240 lb-ft).
2. NOTE: Do not tighten the cam adjuster nut at this time.
NOTE: The cam adjuster must be installed with the small tooth facing toward the frame bracket.
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 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle Alignment Link > Component
Information > Service and Repair > Page 7206
4. Lower the suspension and remove the jack. 5. Install the wheel and tire. 6. Check and, if
necessary, adjust the rear toe.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle
Sensor > Component Information > Locations
Steering Angle Sensor: Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle
Sensor > Component Information > Locations > Page 7211
View 151-15
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle
Sensor > Component Information > Locations > Page 7212
C226
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
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 may result in major service expense. New parts must be
installed with the same part numbers or equivalent part, if replacement is 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 and tire. 2. Remove and discard the 2 stabilizer bar nuts and grommets.
^ To install, tighten to 35 Nm (26 lb-ft) at curb height.
3. Remove and discard the 2 stabilizer bar studs. 4. Remove the 2 stabilizer bar links.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front > Page 7218
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
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 lb-ft) 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 (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front > Page 7219
Stabilizer Link: Service and Repair Rear
Stabilizer Bar and Link - Explorer, Mountaineer
Stabilizer Bar and Link - Explorer, Mountaineer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front > Page 7220
Removal
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure may result in major service expense. New parts must be
installed with the same part numbers or equivalent part, if replacement is 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 or incorrect clamp load and damage
to components may occur.
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 the wheel and tire. 3. Remove and discard the outboard nut and bolt from both upper
arms.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front > Page 7221
4. Remove the stabilizer bar link nut and grommet and the stabilizer bar link.
^ Discard the nut and grommet.
5. Remove and discard the 4 stabilizer bar bracket nuts. 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 filler pipe tube-to-fuel pressure sensor line quick connect coupling. 9. Unclip
the fuel filler pipe tube-to-fuel pressure sensor 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.
Installation
1. With the aid of an assistant, install the stabilizer bar into the LH side of the vehicle. 2. Connect
the fuel filler pipe tube-to-fuel sensor line. 3. Connect the fuel filler pipe tube-to-fuel pressure
sensor line quick connect coupling. 4. Install the 4 stabilizer bar bracket studs. 5. Install the 2
stabilizer bar bushings and the 2 stabilizer bar brackets.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front > Page 7222
6. Install the 4 stabilizer bar bracket nuts.
^ Tighten to 48 Nm (35 lb-ft).
7. Using the jack, 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) in Removal.
8. Install the stabilizer bar link and new link nut and grommet.
^ Tighten the nut to 30 Nm (22 lb-ft).
9. CAUTION: The upper arm outboard bolts must be installed with the bolt head toward the front of
the vehicle or wheel damage may
occur.
Install the 2 upper arm outboard bolts and the 2 upper arm outboard nuts. ^
Tighten to 225 Nm (166 lb-ft).
10. Remove the jack. 11. Install the wheel and tire.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Front
Shock Absorber and Spring Assembly
Removal
WARNING: Do not apply heat or flame to the shock absorber or strut tube. The shock absorber
and strut tube are gas pressurized and could explode if heated. Failure to follow this instruction
may result in serious personal injury.
WARNING: Keep all body parts clear of shock absorbers or strut rods. Shock absorbers or struts
can extend unassisted. Failure to follow this instruction may result in serious personal injury.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Removal and Replacement > Page 7227
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure may result in major service expense. New parts must be
installed with the same part numbers or equivalent part, if replacement is 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. 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. 3. Remove the wheel and tire. 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. 6. Remove
and discard the shock absorber lower bolt and flag nut. 7. Remove and discard the upper ball joint
nut.
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.
Installation
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). This will prevent unequal clamp load and bushing
damage.
NOTE: For additional information on the disassembly and assembly of the shock absorber and
spring assembly, refer to Shock Absorber and Spring Assembly.
1. Install the shock absorber and spring assembly.
2. Connect the upper ball joint to the wheel knuckle and install the upper ball joint nut.
^ Tighten to 55 Nm (41 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Removal and Replacement > Page 7228
3. NOTE: Do not tighten the bolt at this time.
Install the shock absorber lower bolt and flag nut.
4. Using a suitable jack, 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).
5. Install the stabilizer bar link.
^ Tighten to 35 Nm (26 lb-ft).
6. Tighten the shock absorber lower bolt to 350 Nm (258 lb-ft). 7. Install the 3 shock absorber
upper mount nuts.
^ Tighten to 30 Nm (22 lb-ft).
8. Remove the jack. 9. Install the wheel and tire.
10. Check and if necessary, align the front end.
Rear
Shock Absorber and Spring Assembly
Shock Absorber and Spring Assembly
Removal
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure may result in major service expense. New parts must be
installed with the same part numbers or equivalent part, if replacement is 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Removal and Replacement > Page 7229
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 lb-ft).
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 (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Removal and Replacement > Page 7230
Suspension Spring ( Coil / Leaf ): Overhaul
Shock Absorber and Spring Assembly
Shock Absorber and Spring Assembly
Disassembly and Assembly
WARNING: Do not apply heat or flame to the shock absorber or strut tube. The shock absorber
and strut tube are gas pressurized and could explode if heated. Failure to follow this instruction
may result in serious personal injury.
WARNING: Keep all body parts clear of shock absorbers or strut rods. Shock absorbers or struts
can extend unassisted. Failure to follow this instruction may result in serious personal injury.
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure may result in major service expense. New parts must be
installed with the same part numbers or equivalent part, if replacement is 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Removal and Replacement > Page 7231
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: When installing the shock rod nut, make sure the shock rod and bushing are
centered in the upper mount before tightening
the nut or damage to the shock or bushing may occur.
NOTE: Use the holding feature to prevent the shock absorber rod from turning while removing and
installing the nut.
Remove and discard the shock absorber rod nut. ^
To install, tighten to 65 Nm (48 lb-ft).
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: 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 (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Removal and Replacement > Page 7232
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Removal
WARNING: Do not apply heat or flame to the shock absorber or strut tube. The shock absorber
and strut tube are gas pressurized and could explode if heated. Failure to follow this instruction
may result in serious personal injury.
WARNING: Keep all body parts clear of shock absorbers or strut rods. Shock absorbers or struts
can extend unassisted. Failure to follow this instruction may result in serious personal injury.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Removal and Replacement > Page 7237
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure may result in major service expense. New parts must be
installed with the same part numbers or equivalent part, if replacement is 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. 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. 3. Remove the wheel and tire. 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. 6. Remove
and discard the shock absorber lower bolt and flag nut. 7. Remove and discard the upper ball joint
nut.
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.
Installation
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). This will prevent unequal clamp load and bushing
damage.
NOTE: For additional information on the disassembly and assembly of the shock absorber and
spring assembly, refer to Shock Absorber and Spring Assembly.
1. Install the shock absorber and spring assembly.
2. Connect the upper ball joint to the wheel knuckle and install the upper ball joint nut.
^ Tighten to 55 Nm (41 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Removal and Replacement > Page 7238
3. NOTE: Do not tighten the bolt at this time.
Install the shock absorber lower bolt and flag nut.
4. Using a suitable jack, 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).
5. Install the stabilizer bar link.
^ Tighten to 35 Nm (26 lb-ft).
6. Tighten the shock absorber lower bolt to 350 Nm (258 lb-ft). 7. Install the 3 shock absorber
upper mount nuts.
^ Tighten to 30 Nm (22 lb-ft).
8. Remove the jack. 9. Install the wheel and tire.
10. Check and if necessary, align the front end.
Rear Suspension
Shock Absorber and Spring Assembly
Shock Absorber and Spring Assembly
Removal
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure may result in major service expense. New parts must be
installed with the same part numbers or equivalent part, if replacement is 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Removal and Replacement > Page 7239
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 lb-ft).
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 (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Removal and Replacement > Page 7240
Suspension Strut / Shock Absorber: Overhaul
Front
Shock Absorber and Spring Assembly
Shock Absorber and Spring Assembly
Disassembly and Assembly
WARNING: Do not apply heat or flame to the shock absorber or strut tube. The shock absorber
and strut tube are gas pressurized and could explode if heated. Failure to follow this instruction
may result in serious personal injury.
WARNING: Keep all body parts clear of shock absorbers or strut rods. Shock absorbers or struts
can extend unassisted. Failure to follow this instruction may result in serious personal injury.
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure may
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Removal and Replacement > Page 7241
result in major service expense. New parts must be installed with the same part numbers or
equivalent part, if replacement is 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 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: When installing the shock rod nut, make sure the shock rod and bushing are
centered in the upper mount before tightening
the nut or damage to the shock or bushing may occur.
NOTE: Use the holding feature to prevent the shock absorber rod from turning while removing and
installing the nut.
Remove and discard the shock absorber rod nut. ^
To install, tighten to 65 Nm (48 lb-ft).
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: 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 (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Removal and Replacement > Page 7242
Rear
Shock Absorber and Spring Assembly
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Removal and Replacement > Page 7243
Shock Absorber and Spring Assembly
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 (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Removal and Replacement > Page 7244
3. CAUTION: When installing the shock rod nut, make sure the shock rod and bushing are
centered in the upper mount before tightening
the nut or damage to the shock bushing may occur.
NOTE: Use the holding feature to prevent the shock absorber rod from turning while removing and
installing the nut.
Remove and discard the shock absorber rod nut. ^
To install, tighten to 65 Nm (48 lb-ft).
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 (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Removal and Replacement > Page 7245
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
components and systems and their failure may result in major service expense. New parts must be
installed with the same part numbers or equivalent part, if replacement is 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 (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and
Repair > Page 7249
when removed or incorrect clamp load and damage to components may occur.
1. Remove the toe link. 2. Remove the parking brake cable bracket bolt.
^ To install, tighten to 10 Nm (89 lb-inch).
3. Remove and discard the trailing arm bolt.
^ To install, tighten to 300 Nm (222 lb-ft) at curb height.
4. Remove the 3 wheel knuckle bolts and the trailing arm.
^ Discard the bolts.
^ To install, tighten to 275 Nm (203 lb-ft).
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Wheel Bearing and Wheel Hub
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure may result in major service expense. New parts must be
installed with the same part numbers or equivalent part, if replacement is 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 and tire.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front > Page 7254
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 lb-ft).
3. Remove the brake disc.
4. NOTE: Inspect and if necessary, clean area around wheel speed sensor before removing it from
the wheel bearing and hub.
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 lb-ft).
5. Remove the 3 bolts and the wheel bearing and wheel hub.
^ Discard the bolts.
^ To install, tighten to 122 Nm (90 lb-ft).
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front > Page 7255
Wheel Bearing: Service and Repair Rear
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 may result in major service expense. New parts must be
installed with the same part numbers or equivalent part, if replacement is 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 lb-inch).
3. Using the special tool and a suitable press, remove the wheel hub.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front > Page 7256
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 (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information >
Specifications > Rear Axle Wheel End Nut
Axle Nut: Specifications Rear Axle Wheel End Nut
Rear Axle Wheel End Nut ....................................................................................................................
................................................ 275 Nm (203 lb-ft).
Discard the wheel end nut.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information >
Specifications > Rear Axle Wheel End Nut > Page 7262
Axle Nut: Specifications Rear Axle Halfshaft Nut
Rear Axle Halfshaft Nut .......................................................................................................................
................................................ 275 Nm (203 lb-ft).
Install a new halfshaft nut and washer.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Description and Operation
Vehicle Lifting: Description and Operation
JACKING AND LIFTING
WARNING:
- Vehicle may have multiple drive wheels. Do not use engine to power the driveline unless all drive
wheels are elevated off the ground. Drive wheels in contact with ground could cause unexpected
vehicle movement. Failure to follow this instruction may result in serious personal injury.
- When jacking or lifting the vehicle, block all wheels remaining on the ground. Set the parking
brake if the rear wheels will remain on the ground. These actions help prevent unintended vehicle
movement. Failure to follow these instructions may result in serious personal injury.
- Never get underneath a vehicle that is supported only by a jack. The jack could unintentionally
lower. Always support vehicle with floor stands. Failure to follow these instructions may result in
serious personal injury.
- Only raise the vehicle when positioned on a hard, level surface. Attempting to raise the vehicle on
an uneven or soft surface may result in vehicle slipping or falling from the jack or jackstand. Failure
to follow this instruction may result in serious personal injury.
- Identify the correct jacking points by locating the triangle stamped into the uni-body sheet metal or
vehicle frame. Raising a vehicle in any other location may result in vehicle shifting or falling. Failure
to follow this instruction may result in serious personal injury.
CAUTION:
- The jack provided with the vehicle is intended to be used in an emergency for changing a deflated
tire. To avoid damage to the vehicle, never use the jack to hoist the vehicle for any other purpose.
- Under no circumstances should the vehicle ever be lifted by the front or rear control arms,
halfshafts or front wheel constant velocity (CV) joints. Severe damage to the vehicle may result.
- Do not attempt to use jack pressure on either the front bumper or the rear bumper of any vehicle.
Damage to bumper covers will occur.
- To prevent possible damage to the underbody, do not drive the vehicle onto the drive-on lift
without first checking for possible interference.
- When raising a vehicle on a twin-post hoist, use care when positioning the vehicle so that the
hoisting forks do not interfere with the suspension components, mounting brackets or stabilizer
mounting brackets, if equipped. In addition, use care in hoist positioning to avoid possible damage
to the axle carrier or rear cover.
- 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.
Jacking Points
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Description and Operation > Page 7267
Lifting Points
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Monitoring System (TPMS) Sensor
Training
Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor
Training
Tire Pressure Monitoring System (TPMS) Sensor Training
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). For additional information, refer to
Tire Pressure Monitoring System (TPMS) Sensor Activation.
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 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 activation tool, attempt to activate the same sensor with
the activation tool. If the sensor still does not respond, move the vehicle to rotate the wheels at
least 1/4 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. NOTE: 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.
6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the
activation tool must remain in place 180 degrees from
the valve stem.
Place the activation tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press
and release the test button on the special tool. The horn will sound briefly to indicate that the tire
pressure sensor has been recognized by the SJB.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Monitoring System (TPMS) Sensor
Training > Page 7273
7. Within 2 minutes of the horn sounding, place the 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.
8. 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.
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 IDs trained to the SJB and document them
on the applicable warranty claim.
10. 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.
If the sensors are being trained due to the installation of a new SJB, clear any DTCs and perform
the SJB on-demand self test.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 Monitoring System (TPMS) Sensor
Training > Page 7274
Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor
Activation
Tire Pressure Monitoring System (TPMS) Sensor Activation
NOTE: The tire pressure sensors will go into a "sleep mode" after 30 minutes of inactivity to
conserve battery power. The sensors do not transmit information while in sleep mode, it will be
necessary to wake them up so they will transmit the latest tire pressure information.
1. Turn the ignition switch to the ON position. 2. Position the tire pressure monitor activation tool
against the LF tire sidewall 180 degrees from the tire valve stem.
3. NOTE: The activation tool will provide feedback in the form of a flashing green light and a beep
sound for each successful response from a tire
pressure sensor.
Press the test button on the activation tool to activate the sensor, activate the sensor at least 2
times.
4. Repeat Steps 2 and 3 for the remaining tires. 5. If the tire pressure monitoring system (TPMS)
indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom
Chart
in Diagnosis and Testing.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Disassembly
WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous
chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes,
flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any
part of the battery is swallowed, contact a physician immediately. When disposing of TPMS
sensors, follow the correct procedures for hazardous material disposal. Failure to follow these
instructions may result in serious personal injury.
NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of
accordingly.
NOTE: 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.
1. CAUTION: The sensor, cradle and strap may 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 may occur.
Using a pocket screwdriver or similar tool, remove the sensor locking clip.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7277
3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to
the sensor may 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 may 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 (V8-4.6L (2008))
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 7278
3. CAUTION: The sensor, cradle and strap may 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 (V8-4.6L (2008))
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 7279
Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and
Cradle
Tire Pressure Monitoring System (TPMS) Strap and Cradle
Disassembly
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7280
WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous
chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes,
flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any
part of the battery is swallowed, contact a physician immediately. When disposing of TPMS
sensors, follow the correct procedures for hazardous material disposal. Failure to follow these
instructions may result in serious personal injury.
NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of
accordingly.
NOTE: 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.
1. Remove the tire pressure monitoring system (TPMS) sensor. For additional information, refer to
Tire Pressure Monitoring System (TPMS) Sensor.
2. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this
instruction may result in serious personal injury.
WARNING: Wear protective gloves when handling components or parts that have pointed or sharp
edges. Failure to follow this instruction may result in serious personal injury.
Remove a factory installed strap in the following 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.
3. To remove a dealer installed strap, turn the worm gear screw until the strap is fully released from
the worm gear.
^ Discard the strap.
4. 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 may 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 (V8-4.6L (2008))
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 7281
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 degrees 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 and
sensor are mounted at the lowest spot
possible to avoid damaging the sensor during wheel and tire disassembly and assembly.
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 lb-inch).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7282
6. CAUTION: The sensor, cradle and strap may 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 (V8-4.6L (2008))
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
Tire Pressure Monitoring System (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.
Tire Pressure Monitoring System (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.
NOTE: For vehicles with different front and rear tire pressures (such as E-Series and certain
F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the
sensors will result in a false low tire pressure event, which will cause the TPMS indicator to
illuminate.
1. The TPMS indicator remains on continuously for the following 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 the Tire Pressure Monitoring
System (TPMS) Sensor Activation procedure.
Tire Pressure Monitoring System (TPMS) Indicator Flashes
The TPMS indicator flashes for 70 seconds, then remains ON solid when the ignition switch is
turned to the ON position, for the following conditions: 1. Tire Pressure Sensor Fault - If equipped,
the message center will display TIRE PRESSURE 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 not received
any signals from the SJB for more than 5 seconds. If equipped, the message center displays TIRE
PRESSURE 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 PRESSURE
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 (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor
> Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training
Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor
Training
Tire Pressure Monitoring System (TPMS) Sensor Training
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). For additional information, refer to
Tire Pressure Monitoring System (TPMS) Sensor Activation.
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 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 activation tool, attempt to activate the same sensor with
the activation tool. If the sensor still does not respond, move the vehicle to rotate the wheels at
least 1/4 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. NOTE: 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.
6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the
activation tool must remain in place 180 degrees from
the valve stem.
Place the activation tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press
and release the test button on the special tool. The horn will sound briefly to indicate that the tire
pressure sensor has been recognized by the SJB.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor
> Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page
7291
7. Within 2 minutes of the horn sounding, place the 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.
8. 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.
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 IDs trained to the SJB and document them
on the applicable warranty claim.
10. 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.
If the sensors are being trained due to the installation of a new SJB, clear any DTCs and perform
the SJB on-demand self test.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor
> Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page
7292
Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor
Activation
Tire Pressure Monitoring System (TPMS) Sensor Activation
NOTE: The tire pressure sensors will go into a "sleep mode" after 30 minutes of inactivity to
conserve battery power. The sensors do not transmit information while in sleep mode, it will be
necessary to wake them up so they will transmit the latest tire pressure information.
1. Turn the ignition switch to the ON position. 2. Position the tire pressure monitor activation tool
against the LF tire sidewall 180 degrees from the tire valve stem.
3. NOTE: The activation tool will provide feedback in the form of a flashing green light and a beep
sound for each successful response from a tire
pressure sensor.
Press the test button on the activation tool to activate the sensor, activate the sensor at least 2
times.
4. Repeat Steps 2 and 3 for the remaining tires. 5. If the tire pressure monitoring system (TPMS)
indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom
Chart
in Diagnosis and Testing.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Disassembly
WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous
chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes,
flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any
part of the battery is swallowed, contact a physician immediately. When disposing of TPMS
sensors, follow the correct procedures for hazardous material disposal. Failure to follow these
instructions may result in serious personal injury.
NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of
accordingly.
NOTE: 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.
1. CAUTION: The sensor, cradle and strap may 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 may occur.
Using a pocket screwdriver or similar tool, remove the sensor locking clip.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7295
3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to
the sensor may 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 may 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 (V8-4.6L (2008))
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 7296
3. CAUTION: The sensor, cradle and strap may 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 (V8-4.6L (2008))
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 7297
Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and
Cradle
Tire Pressure Monitoring System (TPMS) Strap and Cradle
Disassembly
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7298
WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous
chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes,
flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any
part of the battery is swallowed, contact a physician immediately. When disposing of TPMS
sensors, follow the correct procedures for hazardous material disposal. Failure to follow these
instructions may result in serious personal injury.
NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of
accordingly.
NOTE: 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.
1. Remove the tire pressure monitoring system (TPMS) sensor. For additional information, refer to
Tire Pressure Monitoring System (TPMS) Sensor.
2. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this
instruction may result in serious personal injury.
WARNING: Wear protective gloves when handling components or parts that have pointed or sharp
edges. Failure to follow this instruction may result in serious personal injury.
Remove a factory installed strap in the following 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.
3. To remove a dealer installed strap, turn the worm gear screw until the strap is fully released from
the worm gear.
^ Discard the strap.
4. 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 may 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 (V8-4.6L (2008))
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 7299
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 degrees 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 and
sensor are mounted at the lowest spot
possible to avoid damaging the sensor during wheel and tire disassembly and assembly.
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 lb-inch).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7300
6. CAUTION: The sensor, cradle and strap may 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 (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest for Wheels: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat
Cracking/Peeling
Wheels: Customer Interest Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling
TSB 10-11-2
06/21/10
20 INCH POLISHED ALUMINUM WHEEL - CORROSION AND ETCHING
FORD: 2008-2010 Explorer Sport Trac, Explorer
MERCURY: 2008-2010 Mountaineer
ISSUE Some 2008-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with
20-inch aluminum wheels may exhibit the clear coat peeling off the wheel and/or cracks in the clear
coat that look like spider webs. This may be due to a galvanic corrosion reaction between the
aluminum wheel and the chrome center wheel cap.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Replace the affected wheel or wheels and install new center wheel caps that prevent the corrosion.
1. Inspect wheel(s) for cracked or peeling clear coat. (Figure 1)
NOTE
CONDITIONS ATTRIBUTABLE TO DAMAGE ARE NOT ELIGIBLE FOR COVERAGE UNDER
WARRANTY. REFER TO WARRANTY AND POLICY MANUAL FOR ADDITIONAL
INFORMATION.
2. To service, replace only affected wheel or wheels and install new center wheel caps. Refer to
Workshop Manual, Section 204-04, for wheel removal
and installation procedures including tire/wheel disassembly/assembly to prevent damage to the
tire pressure monitoring system (TPMS) sensor.
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest for Wheels: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat
Cracking/Peeling > Page 7309
101102A 2008-2010 0.6 Hr.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace One Wheel And Center
Wheel Cap (Do Not Use With Any Other Labor Operations)
101102B 2008-2010 0.9 Hr.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Two Wheels And Center
Wheel Caps (Do Not Use With Any Other Labor Operations)
101102C 2008-2010 1.2 Hrs.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Three Wheels And Center
Wheels Caps (Do Not Use With Any Other Labor Operations)
101102D 2008-2010 1.5 Hrs.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Four Wheels And Center
Wheel Caps (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 14
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 7314
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 7319
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 (V8-4.6L (2008))
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 7320
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 7325
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 (V8-4.6L (2008))
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 7326
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 (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat
Cracking/Peeling
Wheels: All Technical Service Bulletins Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling
TSB 10-11-2
06/21/10
20 INCH POLISHED ALUMINUM WHEEL - CORROSION AND ETCHING
FORD: 2008-2010 Explorer Sport Trac, Explorer
MERCURY: 2008-2010 Mountaineer
ISSUE Some 2008-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with
20-inch aluminum wheels may exhibit the clear coat peeling off the wheel and/or cracks in the clear
coat that look like spider webs. This may be due to a galvanic corrosion reaction between the
aluminum wheel and the chrome center wheel cap.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Replace the affected wheel or wheels and install new center wheel caps that prevent the corrosion.
1. Inspect wheel(s) for cracked or peeling clear coat. (Figure 1)
NOTE
CONDITIONS ATTRIBUTABLE TO DAMAGE ARE NOT ELIGIBLE FOR COVERAGE UNDER
WARRANTY. REFER TO WARRANTY AND POLICY MANUAL FOR ADDITIONAL
INFORMATION.
2. To service, replace only affected wheel or wheels and install new center wheel caps. Refer to
Workshop Manual, Section 204-04, for wheel removal
and installation procedures including tire/wheel disassembly/assembly to prevent damage to the
tire pressure monitoring system (TPMS) sensor.
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat
Cracking/Peeling > Page 7332
101102A 2008-2010 0.6 Hr.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace One Wheel And Center
Wheel Cap (Do Not Use With Any Other Labor Operations)
101102B 2008-2010 0.9 Hr.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Two Wheels And Center
Wheel Caps (Do Not Use With Any Other Labor Operations)
101102C 2008-2010 1.2 Hrs.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Three Wheels And Center
Wheels Caps (Do Not Use With Any Other Labor Operations)
101102D 2008-2010 1.5 Hrs.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Four Wheels And Center
Wheel Caps (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 14
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 7337
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 7342
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 (V8-4.6L (2008))
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 7343
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 7348
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 (V8-4.6L (2008))
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 7349
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 (V8-4.6L (2008))
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
Wheel Bearing and Wheel Hub
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure may result in major service expense. New parts must be
installed with the same part numbers or equivalent part, if replacement is 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 and tire.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front > Page 7354
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 lb-ft).
3. Remove the brake disc.
4. NOTE: Inspect and if necessary, clean area around wheel speed sensor before removing it from
the wheel bearing and hub.
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 lb-ft).
5. Remove the 3 bolts and the wheel bearing and wheel hub.
^ Discard the bolts.
^ To install, tighten to 122 Nm (90 lb-ft).
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front > Page 7355
Wheel Bearing: Service and Repair Rear
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 may result in major service expense. New parts must be
installed with the same part numbers or equivalent part, if replacement is 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 lb-inch).
3. Using the special tool and a suitable press, remove the wheel hub.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front > Page 7356
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 (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information >
Technical Service Bulletins > Customer Interest for Wheel Cover: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear
Coat Cracking/Peeling
Wheel Cover: Customer Interest Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling
TSB 10-11-2
06/21/10
20 INCH POLISHED ALUMINUM WHEEL - CORROSION AND ETCHING
FORD: 2008-2010 Explorer Sport Trac, Explorer
MERCURY: 2008-2010 Mountaineer
ISSUE Some 2008-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with
20-inch aluminum wheels may exhibit the clear coat peeling off the wheel and/or cracks in the clear
coat that look like spider webs. This may be due to a galvanic corrosion reaction between the
aluminum wheel and the chrome center wheel cap.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Replace the affected wheel or wheels and install new center wheel caps that prevent the corrosion.
1. Inspect wheel(s) for cracked or peeling clear coat. (Figure 1)
NOTE
CONDITIONS ATTRIBUTABLE TO DAMAGE ARE NOT ELIGIBLE FOR COVERAGE UNDER
WARRANTY. REFER TO WARRANTY AND POLICY MANUAL FOR ADDITIONAL
INFORMATION.
2. To service, replace only affected wheel or wheels and install new center wheel caps. Refer to
Workshop Manual, Section 204-04, for wheel removal
and installation procedures including tire/wheel disassembly/assembly to prevent damage to the
tire pressure monitoring system (TPMS) sensor.
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information >
Technical Service Bulletins > Customer Interest for Wheel Cover: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear
Coat Cracking/Peeling > Page 7365
101102A 2008-2010 0.6 Hr.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace One Wheel And Center
Wheel Cap (Do Not Use With Any Other Labor Operations)
101102B 2008-2010 0.9 Hr.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Two Wheels And Center
Wheel Caps (Do Not Use With Any Other Labor Operations)
101102C 2008-2010 1.2 Hrs.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Three Wheels And Center
Wheels Caps (Do Not Use With Any Other Labor Operations)
101102D 2008-2010 1.5 Hrs.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Four Wheels And Center
Wheel Caps (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 14
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 10-11-2 > Jun > 10 > Wheels - 20 Inch
Wheels Clear Coat Cracking/Peeling
Wheel Cover: All Technical Service Bulletins Wheels - 20 Inch Wheels Clear Coat
Cracking/Peeling
TSB 10-11-2
06/21/10
20 INCH POLISHED ALUMINUM WHEEL - CORROSION AND ETCHING
FORD: 2008-2010 Explorer Sport Trac, Explorer
MERCURY: 2008-2010 Mountaineer
ISSUE Some 2008-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with
20-inch aluminum wheels may exhibit the clear coat peeling off the wheel and/or cracks in the clear
coat that look like spider webs. This may be due to a galvanic corrosion reaction between the
aluminum wheel and the chrome center wheel cap.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Replace the affected wheel or wheels and install new center wheel caps that prevent the corrosion.
1. Inspect wheel(s) for cracked or peeling clear coat. (Figure 1)
NOTE
CONDITIONS ATTRIBUTABLE TO DAMAGE ARE NOT ELIGIBLE FOR COVERAGE UNDER
WARRANTY. REFER TO WARRANTY AND POLICY MANUAL FOR ADDITIONAL
INFORMATION.
2. To service, replace only affected wheel or wheels and install new center wheel caps. Refer to
Workshop Manual, Section 204-04, for wheel removal
and installation procedures including tire/wheel disassembly/assembly to prevent damage to the
tire pressure monitoring system (TPMS) sensor.
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 10-11-2 > Jun > 10 > Wheels - 20 Inch
Wheels Clear Coat Cracking/Peeling > Page 7371
101102A 2008-2010 0.6 Hr.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace One Wheel And Center
Wheel Cap (Do Not Use With Any Other Labor Operations)
101102B 2008-2010 0.9 Hr.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Two Wheels And Center
Wheel Caps (Do Not Use With Any Other Labor Operations)
101102C 2008-2010 1.2 Hrs.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Three Wheels And Center
Wheels Caps (Do Not Use With Any Other Labor Operations)
101102D 2008-2010 1.5 Hrs.
Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Four Wheels And Center
Wheel Caps (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 14
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information
> Specifications > Rear Axle Wheel End Nut
Axle Nut: Specifications Rear Axle Wheel End Nut
Rear Axle Wheel End Nut ....................................................................................................................
................................................ 275 Nm (203 lb-ft).
Discard the wheel end nut.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information
> Specifications > Rear Axle Wheel End Nut > Page 7377
Axle Nut: Specifications Rear Axle Halfshaft Nut
Rear Axle Halfshaft Nut .......................................................................................................................
................................................ 275 Nm (203 lb-ft).
Install a new halfshaft nut and washer.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Specifications
Wheel Fastener: Specifications
Wheel Lug Nuts
...........................................................................................................................................................
135 Nm (100 lb-ft). in a star pattern
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Removal
1. Remove the wheel and tire.
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 165 Nm (122 lb-ft).
3. Remove the brake disc. 4. Using the special tool, remove the wheel stud.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Service and Repair > Front > Page 7383
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 (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Service and Repair > Front > Page 7384
Wheel Fastener: Service and Repair Rear
Wheel Studs
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Service and Repair > Front > Page 7385
Removal
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure may result in major service expense. New parts must be
installed with the same part numbers or equivalent part, if replacement is 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, or incorrect clamp load and
component damage may occur.
1. Remove the wheel and tire.
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. NOTE: 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 (V8-4.6L (2008))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Service and Repair > Front > Page 7386
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 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 A/C system,
except when there is physical evidence of contamination from a failed A/C compressor or damage
to the suction accumulator. Damage to the suction accumulator includes leaks in the suction
accumulator, physical damage to the suction accumulator shell or desiccant, or moisture
contamination. Moisture contamination results only from a complete loss of refrigerant, and
equalization of the refrigerant system pressure with atmospheric pressure for a period longer than
1 hour. If even a slight amount of positive refrigerant pressure is present in the refrigerant system
before repairs are carried out, the suction accumulator should not be replaced.
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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Description and
Operation > Page 7391
Accumulator HVAC: Service and Repair
SUCTION ACCUMULATOR
Removal and Installation
CAUTION: Care must be taken to minimize exposure of the inside of the suction accumulator to
outside air. If multiple air conditioning (A/C) system components are being removed and installed,
the suction accumulator should be installed last. The suction accumulator shipping caps should not
be removed until the fittings are ready to be connected. Evacuation of the A/C system must be
started as soon as the suction accumulator is installed. Excessive exposure of the inside of the
suction accumulator to outside air will result in moisture contamination of the suction accumulator
desiccant.
NOTE: Installation of a new suction accumulator is not required when repairing the A/C system,
except when there is physical evidence of contamination from a failed A/C compressor or damage
to the suction accumulator. Damage to the suction accumulator includes leaks in the suction
accumulator, physical damage to the suction accumulator shell or desiccant, or moisture
contamination. Moisture contamination results only from a complete loss of refrigerant, and
equalization of the refrigerant system pressure with atmospheric pressure for a period longer than
1 hour. If even a slight amount of positive refrigerant pressure is present in the refrigerant system
before repairs are carried out, the suction accumulator should not be replaced.
All vehicles
1. Recover the refrigerant. 2. Remove the PCM. 3. Disconnect the A/C cycling switch electrical
connector. 4. Remove the suction accumulator bolt.
- To install, tighten to 11 Nm (8 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Description and
Operation > Page 7392
5. Remove the PCM bracket bolt.
6. Remove the PCM bracket nut and the PCM bracket.
7. Remove the suction accumulator stud.
- To install, tighten to 11 Nm (8 lb-ft).
4.6L vehicles
8. Remove the suction accumulator-to-compressor line bracket nut at the condenser-to-evaporator
line bracket.
All vehicles
9. Remove the suction accumulator bracket bolt and suction accumulator.
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. 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 (V8-4.6L (2008))
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 151-38
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Locations > Temperature Blend Door Actuator, Driver > Page 7398
View 151-39
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Locations > Temperature Blend Door Actuator, Driver > Page 7399
View 151-40
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Locations > Temperature Blend Door Actuator, Driver > Page 7400
View 151-40
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Locations > Temperature Blend Door Actuator, Driver > Page 7401
View 151-39
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Diagrams > Blend Door Actuator, Rear > Page 7404
C2091
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Diagrams > Blend Door Actuator, Rear > Page 7405
C2092
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Diagrams > Blend Door Actuator, Rear > Page 7406
C3044
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Diagrams > Page 7407
Actuator - Temperature Blend Door, Electronic Automatic Temperature Control (EATC)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 7410
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 (V8-4.6L (2008))
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 7411
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).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7412
4. Remove the 2 auxiliary heater core and evaporator core housing bolts.
- 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 (V8-4.6L (2008))
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 7413
Air Door Actuator / Motor: Service and Repair Vacuum Control Motor - Defroster Door
VACUUM CONTROL MOTOR - DEFROSTER DOOR
Removal and Installation
1. Remove the audio control module (ACM). 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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7414
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 (V8-4.6L (2008))
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 7415
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 (V8-4.6L (2008))
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 7416
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.
Auxiliary Mode Door Actuator
AUXILIARY MODE DOOR ACTUATOR
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7417
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.
- 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).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7418
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.
Vacuum Control Motor - Defroster Door
VACUUM CONTROL MOTOR - DEFROSTER DOOR
Removal and Installation
1. Remove the audio control module (ACM). 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7419
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.
Vacuum Control Motor - Floor Door
VACUUM CONTROL MOTOR - FLOOR DOOR
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7420
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. 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.
Vacuum Control Motor - Panel Door
VACUUM CONTROL MOTOR - PANEL DOOR
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7421
Removal and Installation
1. Remove the audio control module (ACM). 2. Lower the glove compartment. 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 (V8-4.6L (2008))
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 7422
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 (V8-4.6L (2008))
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 7423
- 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.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Vacuum Solenoid Valve, HVAC >
Component Information > Testing and Inspection
Automatic Temperature Control (ATC) Solenoid and Manifold
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component
Information > Locations
Ambient Temperature Sensor / Switch HVAC: Locations
View 151-2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component
Information > Locations > Page 7433
View 151-5
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component
Information > Locations > Page 7434
C132
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component
Information > Locations > Page 7435
Temperature Sensor - Ambient
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component
Information > Locations > Page 7436
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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information
> Locations
View 151-40
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information
> Locations > Page 7441
C3021
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations >
Auxiliary Blower Motor Relay
View 151-40
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations >
Auxiliary Blower Motor Relay > Page 7446
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations >
Auxiliary Blower Motor Relay > Page 7447
View 151-38
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams >
Auxiliary Blower Motor Relay
C3023
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams >
Auxiliary Blower Motor Relay > Page 7450
C2017
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and
Inspection > Blower Motor Relay
Blower Motor Relay: Testing and Inspection Blower Motor Relay
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and
Inspection > Blower Motor Relay > Page 7453
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and
Inspection > Blower Motor Relay > Page 7454
Blower Motor Relay: Testing and Inspection Auxiliary Blower Motor Relay
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and
Inspection > Blower Motor Relay > Page 7455
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations >
Auxiliary Blower Motor Resistor Assembly
View 151-40
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations >
Auxiliary Blower Motor Resistor Assembly > Page 7460
View 151-38
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams >
Front Blower Motor Resistor Assembly
C293
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams >
Front Blower Motor Resistor Assembly > Page 7463
C3022
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams >
Page 7464
Blower Motor Resistor: Description and Operation
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Testing and
Inspection > Resistor - Blower Motor, Front
Resistor - Blower Motor, Front
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Testing and
Inspection > Resistor - Blower Motor, Front > Page 7467
Resistor - Blower Motor, Auxiliary
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 two 4X4 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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and
Repair > Blower Motor Resistor > Page 7470
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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations
View 151-39
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations >
Page 7474
C271
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations >
Page 7475
Blower Motor Switch: Description and Operation
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations >
Page 7476
Switch - Blower Motor, Front Auxiliary
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations >
Page 7477
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information >
Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information >
Locations > Page 7484
C233
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information >
Locations > Page 7485
Temperature Sensor - In-Vehicle
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information >
Locations > Page 7486
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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications
Compressor Clutch: Specifications
Item.......................................................................................................................................................
..............................................................Specification
A/C Compressor Magnetic Clutch
Air gap clearance..................................................................................................................................
...................................0.35-0.65 mm (0.014-0.026 in)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 7491
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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Locations
Compressor Clutch Coil: Locations
View 151-2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Locations > Page 7495
View 151-5
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Locations > Page 7496
C1110
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Locations > Page 7497
Compressor Clutch Coil: Service and Repair
CLUTCH AND CLUTCH FIELD COIL
Special Tool(s)
Special Tool(s)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Locations > Page 7498
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Locations > Page 7499
4. Remove the A/C compressor pulley snap ring. 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 air conditioning (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 electrical connector screw. 9. 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 air conditioning (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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Locations > Page 7500
3 Place the special tool 412-065 on the special tool 412-078.
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 electrical
connector screw. 6. Install the A/C clutch field coil snap ring.
All vehicles
7. 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.
8. Install the A/C clutch pulley snap ring with the bevel side out. 9. Place one nominal thickness
A/C clutch disc and hub spacer inside the clutch hub spline opening.
10. Install the A/C clutch disc and hub assembly. 11. 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 14 Nm (10 lb-ft).
12. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers. 13. Install
the A/C compressor.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
> Page 7504
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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
> Page 7505
Compressor Clutch Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and
Operation
Condenser HVAC: Description and Operation
CONDENSER CORE
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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and
Operation > Page 7509
Condenser HVAC: Service and Repair
CONDENSER CORE
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and
Operation > Page 7510
Part 2
Removal and Installation
1. Recover the refrigerant. 2. Remove the air cleaner (ACL). 3. Remove the 2 coolant expansion
tank bolts and position the coolant expansion tank aside.
- To install, tighten to 7 Nm (62 lb-in).
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 (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7515
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7516
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7517
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7518
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7519
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7520
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7521
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7522
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7523
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7524
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7525
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7526
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7527
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7528
Control Assembly: Connector Views
C294A
C294B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7529
C294C
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7530
C951A
C951B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Page 7531
Control Assembly: Description and Operation
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing
and Inspection > Switch - Function Selector
Switch - Function Selector
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing
and Inspection > Switch - Function Selector > Page 7534
Climate Control Assembly - Front Auxiliary
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
1. Remove the center instrument panel finish panel. 2. Remove the 4 climate control assembly
screws. 3. Remove the climate control assembly. 4. Remove the 3 climate control knobs. 5.
Depress the tabs and remove the blower motor switch.
6. Depress the tabs and remove the function selector switch.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Climate Control Assembly > Page 7537
7. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Climate Control Assembly > Page 7538
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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Climate Control Assembly > Page 7539
Control Assembly: Service and Repair Heating Ventilation Air Conditioning (HVAC) Module
HEATING VENTILATION AIR CONDITIONING (HVAC) MODULE
Removal and Installation
NOTE: If installing a new HVAC module, the new module must be configured for the vehicle.
1. Remove the center instrument panel finish panel. 2. Remove the 4 HVAC module screws. 3.
Remove the HVAC module. 4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations >
Page 7543
Control Module HVAC: Diagrams
C228A
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations >
Page 7544
C228B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 may cause axial scratches
across the O-ring seal grooves, resulting in
refrigerant leaks.
Push the Refrigerant Coupling Spring Remover 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 air conditioning (A/C) tube lock
coupling spring; this may cause axial
scratches across the O-ring seal grooves resulting in refrigerant leaks.
Remove the spring lock coupling spring with a small hooked wire.
Connect
1. Install the spring lock coupling spring.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Page 7548
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.
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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest for Evaporator Case: > 08-17-5 > Sep > 08 > A/C - Water Leak Onto Driver's Side Floor
Evaporator Case: Customer Interest A/C - Water Leak Onto Driver's Side Floor
TSB 08-17-5
09/01/08
WATER LEAK - DRIVERSIDE FLOORBOARD DURING RIGHT HAND TURNS OR AFTER
EXTENDED DRIVING WITH AC ON - VEHICLES BUILT PRIOR TO 7/21/2008
FORD: 2008 Explorer Sport Trac, Explorer
MERCURY: 2008 Mountaineer
ISSUE Some 2008 Explorer, Mountaineer, and Sport Trac vehicles built prior to 7/21/2008 may
exhibit a water leak on the left front floorboard and/or the customer's shoes from the A/C plenum
assembly. This may be due to condensation from the A/C lines leaking between the plenum case
and the A/C evaporator gasket at the bulkhead.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
The evaporator gasket may get caught on or push through the A/C line access hole at the bulk
head during plant installation. This will create a gap at the bottom of the evaporator gasket. (Figure
1)
NOTE
THE GASKET CAN BE REPOSITIONED FROM THE ENGINE COMPARTMENT WITH A
FINGER. (FIGURE 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest for Evaporator Case: > 08-17-5 > Sep > 08 > A/C - Water Leak Onto Driver's Side Floor >
Page 7557
NOTE
THE 4.6L ENGINE A/C EVAPORATOR GASKET CAN BE ACCESSED FROM THE DRIVER SIDE
OF THE ENGINE COMPARTMENT AND THE 4.0L ENGINE GASKET MUST BE ACCESSED
FROM THE PASSENGER SIDE OF THE ENGINE COMPARTMENT.
Position the A/C evaporator gasket so it is compressed between the bulkhead and plenum
assembly. The bulkhead access hole has a rolled lip which will seal the condensation from leaking
between the plenum case and the bulkhead.
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
081705A 2008 Explorer, 0.2 Hr.
Mountaineer and Explorer Sport Trac: Reposition the Plenum Case Evaporator Gasket at the
Vehicle Bulkhead.
DEALER CODING
CONDITION
BASIC PART NO. CODE
18658 07
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Evaporator Case: > 08-17-5 > Sep > 08 > A/C - Water Leak Onto Driver's Side
Floor
Evaporator Case: All Technical Service Bulletins A/C - Water Leak Onto Driver's Side Floor
TSB 08-17-5
09/01/08
WATER LEAK - DRIVERSIDE FLOORBOARD DURING RIGHT HAND TURNS OR AFTER
EXTENDED DRIVING WITH AC ON - VEHICLES BUILT PRIOR TO 7/21/2008
FORD: 2008 Explorer Sport Trac, Explorer
MERCURY: 2008 Mountaineer
ISSUE Some 2008 Explorer, Mountaineer, and Sport Trac vehicles built prior to 7/21/2008 may
exhibit a water leak on the left front floorboard and/or the customer's shoes from the A/C plenum
assembly. This may be due to condensation from the A/C lines leaking between the plenum case
and the A/C evaporator gasket at the bulkhead.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
The evaporator gasket may get caught on or push through the A/C line access hole at the bulk
head during plant installation. This will create a gap at the bottom of the evaporator gasket. (Figure
1)
NOTE
THE GASKET CAN BE REPOSITIONED FROM THE ENGINE COMPARTMENT WITH A
FINGER. (FIGURE 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Evaporator Case: > 08-17-5 > Sep > 08 > A/C - Water Leak Onto Driver's Side
Floor > Page 7563
NOTE
THE 4.6L ENGINE A/C EVAPORATOR GASKET CAN BE ACCESSED FROM THE DRIVER SIDE
OF THE ENGINE COMPARTMENT AND THE 4.0L ENGINE GASKET MUST BE ACCESSED
FROM THE PASSENGER SIDE OF THE ENGINE COMPARTMENT.
Position the A/C evaporator gasket so it is compressed between the bulkhead and plenum
assembly. The bulkhead access hole has a rolled lip which will seal the condensation from leaking
between the plenum case and the bulkhead.
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
081705A 2008 Explorer, 0.2 Hr.
Mountaineer and Explorer Sport Trac: Reposition the Plenum Case Evaporator Gasket at the
Vehicle Bulkhead.
DEALER CODING
CONDITION
BASIC PART NO. CODE
18658 07
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and
Operation > Page 7567
Evaporator Core: Testing and Inspection
A/C EVAPORATOR/CONDENSER CORE - ON VEHICLE LEAK TEST
1. Recover the refrigerant. 2. Disconnect the suspect A/C evaporator core or A/C condenser core
from the A/C system. 3. Clean the spring lock couplings. Refer to Spring Lock Coupling. 4. Connect
the appropriate test fittings from the R-12/R-134a Air Conditioning Test Fitting Set to the evaporator
or condenser tube connections.
5. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to
the test fittings. If available, use hoses without
shut-off valves. If hoses with shut-off valves are used, make sure the valve opens when attached to
the test fittings or install an adapter which will activate the valve. The test is not valid if the shut-off
valve does not open.
Connect the red and blue hoses from the R-134a Manifold Gauge Set to the test fittings on the A/C
evaporator core or A/C condenser core. Connect the yellow hose to a known good vacuum pump.
6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for
a minimum of 45 minutes after the gauge set low
pressure gauge indicates 101 kPa (30 in-Hg). The 45 minute evacuation is necessary to remove
any refrigerant from oil left in the A/C evaporator core or A/C condenser core. If the refrigerant is
not completely removed from the oil, outgassing will degrade the vacuum and appear as a
refrigerant leak.
7. If the low pressure gauge reading will not drop to 101 kPa (30 in-Hg) when the valves on the
gauge and manifold set are open and the vacuum
pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure
rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set
connections before replacing the A/C evaporator core or A/C condenser core.
8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump.
Observe the low pressure gauge; it should remain at the
101 kPa (30 in-Hg) mark. If the low pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from the 101
kPa (30 in-Hg) position in 10 minutes, a leak is indicated.
- If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge.
- If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open for an
additional 30 minutes to remove any remaining refrigerant from the oil in the A/C evaporator core or
A/C condenser core. Then recheck for loss of vacuum.
- If a very small leak is suspected, allow the system to set overnight with vacuum applied and
check for vacuum loss.
9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure,
install a new A/C evaporator core or A/C
condenser core.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and
Operation > Page 7568
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 7577
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 7583
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Description and Operation
Expansion Block/Orifice Tube: Description and Operation
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.
A/C Pressure Transducer
The A/C pressure transducer is used by the PCM to monitor the discharge pressure in the
high-pressure side of the refrigerant system. When the A/C pressure transducer is reading a
discharge pressure above acceptable levels, the PCM will disengage the A/C compressor clutch.
The A/C pressure transducer is installed on a Schrader-type valve core fitting on the
compressor-to-condenser discharge line. It is not necessary to recover the refrigerant before
removing the A/C pressure transducer.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Description and Operation > Page 7590
Expansion Block/Orifice Tube: Service and Repair
EVAPORATOR CORE ORIFICE
Special Tool(s)
Special Tool(s)
Removal
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. 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Description and Operation > Page 7591
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 18 Nm (13 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 (V8-4.6L (2008))
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 (TXV). This filter must be inspected before a new TXV is installed.
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 TXV. 4. Remove the 4 clips and the TXV cover. 5.
Remove the insulating tape.
- Retain the tape for reuse.
6. Remove the temperature sensing bulb clip and detach the temperature sensing bulb from the
evaporator outlet line.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair
> Page 7595
7. Disconnect the 2 TXV fittings and remove the TXV.
- 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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Testing and Inspection
Heater Core: Testing and Inspection
HEATER CORE
1. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores were
good and did not require replacement. If a heater
core leak is suspected, the heater core must be tested by carrying out the plugged heater core
component test before the heater core pressure test. Carry out a system inspection by checking
the heater system thoroughly as follows:
Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A
coolant leak in the heater water hose could follow the heater core tube to the heater core and
appear as a leak in the heater core.
2. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of
non-specification clamps can cause leakage at
the heater water hose connection and damage the heater core.
Check the integrity of the heater water hose clamps.
Heater Core - Plugged
1. Check to see that the engine coolant is at the correct level. 2. Start the engine and turn on the
heater. 3. When the engine coolant reaches operating temperature, feel the heater core inlet and
outlet hose to see if they are hot.
If the inlet hose is not hot: the heater control valve may be stuck closed.
- the thermostat is not working correctly.
If the outlet hose is not hot: the heater core may have an air pocket.
- the heater core may be restricted or plugged.
Heater Core - Pressure Test
Use the Radiator/Heater Core Pressure Tester to perform the pressure test.
1. NOTE: Due to space limitations, a bench test may be necessary for pressure testing.
Clamp off the heater hoses.
2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater hose,
approximately 101 mm (4 in) long on each heater core tube. 4. Fill the heater core and heater
water hoses with water and install Plug BT-7422-B and Adapter BT-7422-A from the
Radiator/Heater Core
Pressure Tester in the heater water hose ends. Secure the heater water hoses, plug and adapter
with hose clamps.
5. Attach the pump and gauge assembly from the Radiator/Heater Core Pressure Tester to the
adapter. 6. Close the bleed valve at the base of the gauge. Pump 138 kPa (20 psi) of air pressure
into the heater core. 7. Observe the pressure gauge for a minimum of 3 minutes. 8. If the pressure
drops, check the heater water hose connections to the core tubes for leaks. If the heater water
hoses do not leak, remove the heater
core from the vehicle and perform the bench test.
Heater Core - Bench Test
1. Remove the heater core from the vehicle. 2. Drain all of the coolant from the heater core. 3.
Connect the 101 mm (4 in) test heater water hoses with plug and adapter to the core tubes. Then
connect the radiator/heater core pressure tester to
the adapter.
4. Apply 138 kPa (20 psi) of air pressure to the heater core. Submerge the heater core in water.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Testing and Inspection
> Page 7602
5. If a leak is observed, replace the heater core.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Heater Core > Page 7605
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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Heater Core > Page 7606
Heater Core: Service and Repair Auxiliary Heater Core
AUXILIARY HEATER CORE
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Heater Core > Page 7607
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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Heater Core > Page 7608
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair >
Auxiliary Heater Outlet and Inlet Line - Front > Page 7613
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair >
Auxiliary Heater Outlet and Inlet Line - Front > Page 7614
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.
- 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 (V8-4.6L (2008))
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 PRESSURE RELIEF VALVE
NOTE: If the A/C compressor is operating within limits and the A/C pressure relief valve is venting,
or if the A/C pressure relief valve is leaking around the threads, replace the A/C pressure relief
valve and O-ring. If the A/C pressure relief valve still vents after it is replaced, diagnose the
refrigerant system for a restriction.
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.
The A/C pressure relief valve is a separate component and can be replaced separately from the
A/C compressor. It is necessary to recover the refrigerant before removing the A/C pressure relief
valve.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information >
Description and Operation > Page 7618
High Pressure Safety Valve HVAC: Service and Repair
AIR CONDITIONING (A/C) PRESSURE RELIEF VALVE
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the
A/C compressor pressure relief valve and O-ring seal.
- To install, tighten to 10 Nm (89 lb-in).
4. NOTE: A new O-ring seal will already be installed on the new A/C pressure relief valve service
part.
To install, reverse the removal procedure. Lubricate the refrigerant system with the correct amount of clean PAG oil.
5. Evacuate, leak test and charge the refrigerant system.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the air
cleaner (ACL) and ACL outlet tube. 4. Remove the compressor-to-condenser discharge line
bracket nut and detach the bracket.
- To install, tighten to 9 Nm (80 lb-in).
5. Remove the compressor outlet fitting nut and disconnect the fitting.
- Discard the O-ring seal and gasket seal.
- To install, tighten to 15 Nm (11 lb-ft).
6. Remove the 2 coolant expansion tank bolts and position the coolant expansion tank aside.
- To install, tighten to 7 Nm (62 lb-in).
7. Disconnect the A/C pressure transducer electrical connector. 8. Remove the condenser inlet
fitting nut and disconnect the fitting.
- Discard the O-ring seal.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor to Condenser Discharge Line > Page 7623
- To install, tighten to 8 Nm (71 lb-in).
9. NOTE: The LH clip should be disconnected from the line. The RH clip should be disconnected
from the cooling module.
Detach the 2 compressor-to-condenser discharge line clips at the cooling module.
10. Remove the compressor-to-condenser discharge line. 11. 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.
12. Evacuate, leak test and charge the refrigerant system.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor to Condenser Discharge Line > Page 7624
Hose/Line HVAC: Service and Repair Condenser To Evaporator Line
CONDENSER TO EVAPORATOR LINE
Removal and Installation
All vehicles
1. Remove the air cleaner (ACL) and ACL outlet tube. 2. Recover the refrigerant. 3. Remove the
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.
7. Remove the condenser-to-evaporator line bracket nut.
- To install, tighten to 7 Nm (62 lb-in).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor to Condenser Discharge Line > Page 7625
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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor to Condenser Discharge Line > Page 7626
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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor to Condenser Discharge Line > Page 7627
Part 2
Removal and Installation
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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor to Condenser Discharge Line > Page 7628
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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor to Condenser Discharge Line > Page 7629
Part 2
Removal and Installation
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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor to Condenser Discharge Line > Page 7630
Hose/Line HVAC: Service and Repair
Compressor to Condenser Discharge Line
COMPRESSOR TO CONDENSER DISCHARGE LINE
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the air
cleaner (ACL) and ACL outlet tube. 4. Remove the compressor-to-condenser discharge line
bracket nut and detach the bracket.
- To install, tighten to 9 Nm (80 lb-in).
5. Remove the compressor outlet fitting nut and disconnect the fitting.
- Discard the O-ring seal and gasket seal.
- To install, tighten to 15 Nm (11 lb-ft).
6. Remove the 2 coolant expansion tank bolts and position the coolant expansion tank aside.
- To install, tighten to 7 Nm (62 lb-in).
7. Disconnect the A/C pressure transducer electrical connector. 8. Remove the condenser inlet
fitting nut and disconnect the fitting.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor to Condenser Discharge Line > Page 7631
- Discard the O-ring seal.
- To install, tighten to 8 Nm (71 lb-in).
9. NOTE: The LH clip should be disconnected from the line. The RH clip should be disconnected
from the cooling module.
Detach the 2 compressor-to-condenser discharge line clips at the cooling module.
10. Remove the compressor-to-condenser discharge line. 11. 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.
12. Evacuate, leak test and charge the refrigerant system.
Condenser To Evaporator Line
CONDENSER TO EVAPORATOR LINE
Removal and Installation
All vehicles
1. Remove the air cleaner (ACL) and ACL outlet tube. 2. Recover the refrigerant. 3. Remove the
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor to Condenser Discharge Line > Page 7632
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.
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.
Auxiliary Evaporator Outlet and Inlet Line - Front
AUXILIARY EVAPORATOR OUTLET AND INLET LINE - FRONT
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor to Condenser Discharge Line > Page 7633
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor to Condenser Discharge Line > Page 7634
Part 2
Removal and Installation
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.
Auxiliary Evaporator Outlet and Inlet Line - Rear
AUXILIARY EVAPORATOR OUTLET AND INLET LINE - REAR
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor to Condenser Discharge Line > Page 7635
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor to Condenser Discharge Line > Page 7636
Part 2
Removal and Installation
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.
Suction Accumulator To Compressor Line
SUCTION ACCUMULATOR TO COMPRESSOR LINE
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor to Condenser Discharge Line > Page 7637
Removal and Installation
1. Recover the refrigerant. 2. Remove the suction accumulator outlet fitting nut.
- To install, tighten to 8 Nm (71 lb-in).
3. Disconnect the auxiliary evaporator outlet line fitting.
- Discard the O-ring seals.
4. Remove the suction accumulator-to-compressor line bracket nut.
- To install, tighten to 7 Nm (62 lb-in).
5. Remove the suction accumulator-to-compressor line middle fitting nut and disconnect the fitting.
- Discard the O-ring seal.
- To install, tighten to 8 Nm (71 lb-in).
6. Remove the rear suction accumulator-to-compressor line.
- Discard the O-ring seal.
7. NOTE: The compressor suction fitting nut can be accessed through the RH wheel well.
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).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor to Condenser Discharge Line > Page 7638
8. Remove the front suction accumulator-to-compressor line. 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.
Suction Accumulator To Evaporator Line
SUCTION ACCUMULATOR TO EVAPORATOR LINE
Removal and Installation
All vehicles
1. Remove the suction accumulator. 2. 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).
3. Remove the ground strap bolt at the dash panel.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor to Condenser Discharge Line > Page 7639
4. Disconnect the evaporator outlet fitting.
- Discard the O-ring seals.
Vehicles with 4.0L engine
5. Disconnect he evaporative emissions return line fitting at the intake manifold.
6. Remove the fuel line bracket bolt at the rear of the RH valve cover.
7. Remove the wire harness bolt at the rear of the RH cylinder head.
All vehicles
8. Remove the suction accumulator-to-evaporator line. 9. To install, reverse the removal procedure.
- Install new O-ring seals.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor to Condenser Discharge Line > Page 7640
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical
Service Bulletins > Customer Interest for Housing Assembly HVAC: > 08-17-5 > Sep > 08 > A/C - Water Leak Onto Driver's
Side Floor
Housing Assembly HVAC: Customer Interest A/C - Water Leak Onto Driver's Side Floor
TSB 08-17-5
09/01/08
WATER LEAK - DRIVERSIDE FLOORBOARD DURING RIGHT HAND TURNS OR AFTER
EXTENDED DRIVING WITH AC ON - VEHICLES BUILT PRIOR TO 7/21/2008
FORD: 2008 Explorer Sport Trac, Explorer
MERCURY: 2008 Mountaineer
ISSUE Some 2008 Explorer, Mountaineer, and Sport Trac vehicles built prior to 7/21/2008 may
exhibit a water leak on the left front floorboard and/or the customer's shoes from the A/C plenum
assembly. This may be due to condensation from the A/C lines leaking between the plenum case
and the A/C evaporator gasket at the bulkhead.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
The evaporator gasket may get caught on or push through the A/C line access hole at the bulk
head during plant installation. This will create a gap at the bottom of the evaporator gasket. (Figure
1)
NOTE
THE GASKET CAN BE REPOSITIONED FROM THE ENGINE COMPARTMENT WITH A
FINGER. (FIGURE 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical
Service Bulletins > Customer Interest for Housing Assembly HVAC: > 08-17-5 > Sep > 08 > A/C - Water Leak Onto Driver's
Side Floor > Page 7649
NOTE
THE 4.6L ENGINE A/C EVAPORATOR GASKET CAN BE ACCESSED FROM THE DRIVER SIDE
OF THE ENGINE COMPARTMENT AND THE 4.0L ENGINE GASKET MUST BE ACCESSED
FROM THE PASSENGER SIDE OF THE ENGINE COMPARTMENT.
Position the A/C evaporator gasket so it is compressed between the bulkhead and plenum
assembly. The bulkhead access hole has a rolled lip which will seal the condensation from leaking
between the plenum case and the bulkhead.
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
081705A 2008 Explorer, 0.2 Hr.
Mountaineer and Explorer Sport Trac: Reposition the Plenum Case Evaporator Gasket at the
Vehicle Bulkhead.
DEALER CODING
CONDITION
BASIC PART NO. CODE
18658 07
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Housing Assembly HVAC: > 08-17-5 > Sep > 08 > A/C - Water Leak
Onto Driver's Side Floor
Housing Assembly HVAC: All Technical Service Bulletins A/C - Water Leak Onto Driver's Side
Floor
TSB 08-17-5
09/01/08
WATER LEAK - DRIVERSIDE FLOORBOARD DURING RIGHT HAND TURNS OR AFTER
EXTENDED DRIVING WITH AC ON - VEHICLES BUILT PRIOR TO 7/21/2008
FORD: 2008 Explorer Sport Trac, Explorer
MERCURY: 2008 Mountaineer
ISSUE Some 2008 Explorer, Mountaineer, and Sport Trac vehicles built prior to 7/21/2008 may
exhibit a water leak on the left front floorboard and/or the customer's shoes from the A/C plenum
assembly. This may be due to condensation from the A/C lines leaking between the plenum case
and the A/C evaporator gasket at the bulkhead.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
The evaporator gasket may get caught on or push through the A/C line access hole at the bulk
head during plant installation. This will create a gap at the bottom of the evaporator gasket. (Figure
1)
NOTE
THE GASKET CAN BE REPOSITIONED FROM THE ENGINE COMPARTMENT WITH A
FINGER. (FIGURE 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Housing Assembly HVAC: > 08-17-5 > Sep > 08 > A/C - Water Leak
Onto Driver's Side Floor > Page 7655
NOTE
THE 4.6L ENGINE A/C EVAPORATOR GASKET CAN BE ACCESSED FROM THE DRIVER SIDE
OF THE ENGINE COMPARTMENT AND THE 4.0L ENGINE GASKET MUST BE ACCESSED
FROM THE PASSENGER SIDE OF THE ENGINE COMPARTMENT.
Position the A/C evaporator gasket so it is compressed between the bulkhead and plenum
assembly. The bulkhead access hole has a rolled lip which will seal the condensation from leaking
between the plenum case and the bulkhead.
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
081705A 2008 Explorer, 0.2 Hr.
Mountaineer and Explorer Sport Trac: Reposition the Plenum Case Evaporator Gasket at the
Vehicle Bulkhead.
DEALER CODING
CONDITION
BASIC PART NO. CODE
18658 07
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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.
- Lubricate the coolant hoses with plain water only if needed.
1. Recover the refrigerant. 2. Drain the engine coolant. 3. Remove the instrument panel. 4. Detach
the wiring harness bracket and position the harness aside.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Heater Core and Evaporator Core Housing > Page 7658
5. Remove the heater tube bracket nut.
6. Remove the dash panel A/C line bracket nut.
- 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.
10. Disconnect the 2 vacuum connectors.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Heater Core and Evaporator Core Housing > Page 7659
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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Heater Core and Evaporator Core Housing > Page 7660
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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Heater Core and Evaporator Core Housing > Page 7661
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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Heater Core and Evaporator Core Housing > Page 7662
Removal and Installation
NOTE: 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.
- To install, tighten to 6 Nm (53 lb-in).
10. Remove the auxiliary heater core and evaporator core housing nut.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Heater Core and Evaporator Core Housing > Page 7663
- 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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity
Specifications
Refrigerant: Capacity Specifications
R-134a Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada)..........WSH-M17B19-A
(Specification) - 0.88 kg (31 oz) (vehicles without auxiliary
systems) (Fill Capacity)
R-134a Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada)...............WSH-M17B19-A
(Specification) - 1.33 kg (47 oz) (vehicles with auxiliary
systems) (Fill Capacity)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity
Specifications > Page 7668
Refrigerant: Fluid Type Specifications
R-134a Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada)..........WSH-M17B19-A
(Specification) - 0.88 kg (31 oz) (vehicles without auxiliary
systems) (Fill Capacity)
R-134a Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada)...............WSH-M17B19-A
(Specification) - 1.33 kg (47 oz) (vehicles with auxiliary
systems) (Fill Capacity)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications >
Capacity Specifications
Refrigerant Oil: Capacity Specifications
Climate Control System
PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D....................WSH-M1C231-B
(Specification) - 266 ml (9 fl oz) (vehicles without auxiliary
systems) (Fill Capacity)
PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D.......................WSH-M1C231-B
(Specification) - 473 ml (16 fl oz) (vehicles with auxiliary
systems) (Fill Capacity)
Auxiliary Climate Control
PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D.............WSH-M1C231-B
(Specification) - 47 ml (16 fl oz) (with auxiliary climate control)
(Fill Capacity)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications >
Capacity Specifications > Page 7673
Refrigerant Oil: Fluid Type Specifications
Climate Control System
PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D....................WSH-M1C231-B
(Specification) - 266 ml (9 fl oz) (vehicles without auxiliary
systems) (Fill Capacity)
PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D.......................WSH-M1C231-B
(Specification) - 473 ml (16 fl oz) (vehicles with auxiliary
systems) (Fill Capacity)
Auxiliary Climate Control
PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D.............WSH-M1C231-B
(Specification) - 47 ml (16 fl oz) (with auxiliary climate control)
(Fill Capacity)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Locations
Refrigerant Pressure Sensor / Switch: Locations
View 151-2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Locations > Page 7677
View 151-5
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Diagrams > A/C Clutch Cycling Pressure Switch
C130
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Diagrams > A/C Clutch Cycling Pressure Switch > Page 7680
C1078
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Description and Operation > A/C Cycling Switch
Refrigerant Pressure Sensor / Switch: Description and Operation A/C Cycling Switch
A/C CYCLING SWITCH
The A/C cycling switch is used to prevent icing of the evaporator core by cycling OFF the A/C
compressor clutch when the suction pressure in the low-pressure side of the refrigerant system
drops below acceptable levels. When the A/C cycling switch circuit is open, the PCM will disengage
the A/C compressor clutch.
The A/C cycling switch is installed on a Schrader-type valve core fitting on the suction accumulator.
It is not necessary to recover the refrigerant before removing the A/C cycling switch.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Description and Operation > A/C Cycling Switch > Page 7683
Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning (A/C) Cycling
Switch
Air Conditioning (A/C) Cycling Switch
The A/C cycling switch may be wired to either the ACCS or ACPSW PCM input. When the A/C
cycling switch opens, the PCM turns off the A/C clutch. For information on the specific function of
the A/C cycling switch, refer to Heating and Air Conditioning, Climate Control System Air
Conditioning System Overview. Also, refer to the applicable Vehicle/Diagrams for vehicle specific
wiring.
If the ACCS signal is not received by the PCM, the PCM circuit will not allow the A/C to operate.
Some applications do not have a dedicated (separate) input to the PCM indicating that A/C is
requested. This information is received by the PCM through the communication link.
Air Conditioning (A/C) High Pressure Switch
The A/C high pressure switch is used for additional A/C system pressure control. The A/C high
pressure switch is either dual function for multiple speed, relay controlled electric fan applications,
or single function for all others.
For refrigerant containment control, the normally closed high pressure contacts open at a
predetermined A/C pressure. This results in the A/C turning off, preventing the A/C pressure from
rising to a level that would open the A/C high pressure relief valve.
For fan control, the normally open medium pressure contacts close at a predetermined A/C
pressure. This grounds the ACPSW circuit input to the PCM. The PCM then turns on the high
speed fan to help reduce the pressure.
For additional information, refer to Heating and Air Conditioning, Climate Control System, Air
Conditioning System Overview or Vehicle/Diagrams.
Air Conditioning Pressure (ACP) Transducer Sensor
A/C Pressure Transducer Sensor Output Voltage
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Description and Operation > A/C Cycling Switch > Page 7684
Typical ACP Transducer Sensor
The ACP transducer sensor is located in the high pressure (discharge) side of the A/C system. The
ACP transducer sensor provides a voltage signal to the PCM that is proportional to the A/C
pressure. The PCM uses this information for A/C clutch control, fan control and idle speed control.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Auxiliary Blower Motor Relay
View 151-40
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Auxiliary Blower Motor Relay > Page 7690
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Auxiliary Blower Motor Relay > Page 7691
View 151-38
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Diagrams > Auxiliary Blower Motor Relay
C3023
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Diagrams > Auxiliary Blower Motor Relay > Page 7694
C2017
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > Blower Motor Relay
Blower Motor Relay: Testing and Inspection Blower Motor Relay
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > Blower Motor Relay > Page 7697
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > Blower Motor Relay > Page 7698
Blower Motor Relay: Testing and Inspection Auxiliary Blower Motor Relay
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > Blower Motor Relay > Page 7699
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Page 7703
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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Page 7704
Compressor Clutch Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Locations > Page 7708
Control Module HVAC: Diagrams
C228A
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Locations > Page 7709
C228B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations
Ambient Temperature Sensor / Switch HVAC: Locations
View 151-2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations > Page 7714
View 151-5
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations > Page 7715
C132
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations > Page 7716
Temperature Sensor - Ambient
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations > Page 7717
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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch >
Component Information > Locations
View 151-39
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch >
Component Information > Locations > Page 7721
C271
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch >
Component Information > Locations > Page 7722
Blower Motor Switch: Description and Operation
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch >
Component Information > Locations > Page 7723
Switch - Blower Motor, Front Auxiliary
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch >
Component Information > Locations > Page 7724
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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor /
Switch > Component Information > Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor /
Switch > Component Information > Locations > Page 7728
C233
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor /
Switch > Component Information > Locations > Page 7729
Temperature Sensor - In-Vehicle
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor /
Switch > Component Information > Locations > Page 7730
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Locations
Refrigerant Pressure Sensor / Switch: Locations
View 151-2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Locations > Page 7737
View 151-5
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Diagrams > A/C Clutch Cycling Pressure Switch
C130
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Diagrams > A/C Clutch Cycling Pressure Switch > Page 7740
C1078
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch
Refrigerant Pressure Sensor / Switch: Description and Operation A/C Cycling Switch
A/C CYCLING SWITCH
The A/C cycling switch is used to prevent icing of the evaporator core by cycling OFF the A/C
compressor clutch when the suction pressure in the low-pressure side of the refrigerant system
drops below acceptable levels. When the A/C cycling switch circuit is open, the PCM will disengage
the A/C compressor clutch.
The A/C cycling switch is installed on a Schrader-type valve core fitting on the suction accumulator.
It is not necessary to recover the refrigerant before removing the A/C cycling switch.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 7743
Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning (A/C) Cycling
Switch
Air Conditioning (A/C) Cycling Switch
The A/C cycling switch may be wired to either the ACCS or ACPSW PCM input. When the A/C
cycling switch opens, the PCM turns off the A/C clutch. For information on the specific function of
the A/C cycling switch, refer to Heating and Air Conditioning, Climate Control System Air
Conditioning System Overview. Also, refer to the applicable Vehicle/Diagrams for vehicle specific
wiring.
If the ACCS signal is not received by the PCM, the PCM circuit will not allow the A/C to operate.
Some applications do not have a dedicated (separate) input to the PCM indicating that A/C is
requested. This information is received by the PCM through the communication link.
Air Conditioning (A/C) High Pressure Switch
The A/C high pressure switch is used for additional A/C system pressure control. The A/C high
pressure switch is either dual function for multiple speed, relay controlled electric fan applications,
or single function for all others.
For refrigerant containment control, the normally closed high pressure contacts open at a
predetermined A/C pressure. This results in the A/C turning off, preventing the A/C pressure from
rising to a level that would open the A/C high pressure relief valve.
For fan control, the normally open medium pressure contacts close at a predetermined A/C
pressure. This grounds the ACPSW circuit input to the PCM. The PCM then turns on the high
speed fan to help reduce the pressure.
For additional information, refer to Heating and Air Conditioning, Climate Control System, Air
Conditioning System Overview or Vehicle/Diagrams.
Air Conditioning Pressure (ACP) Transducer Sensor
A/C Pressure Transducer Sensor Output Voltage
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 7744
Typical ACP Transducer Sensor
The ACP transducer sensor is located in the high pressure (discharge) side of the A/C system. The
ACP transducer sensor provides a voltage signal to the PCM that is proportional to the A/C
pressure. The PCM uses this information for A/C clutch control, fan control and idle speed control.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC >
Component Information > Locations
View 151-13
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC >
Component Information > Locations > Page 7748
C286
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 A/C 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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations
View 151-13
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations >
Page 7755
C286
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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: Carefully read cautionary information on product label. For EMERGENCY MEDICAL
INFORMATION seek medical
advice. Consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these
instructions may result in serious 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 section.
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Solenoid Valve HVAC > Component Information >
Locations
View 151-13
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Solenoid Valve HVAC > Component Information >
Locations > Page 7765
C2093
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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.
- Deployable devices (such as air bag modules, pretensioners) may deploy alone or in various
combinations depending on the impact event.
- Always refer to the appropriate Vehicle System procedures prior to carrying out vehicle repairs
affecting the SRS and safety belt system.
- 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 Vehicle System. See: Air Bag Systems/Service and Repair/Occupant
Classification Sensor (OCS) System Reset
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 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 weight sensor bolts.
- 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.
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
- 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 (V8-4.6L (2008))
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 7771
Repairs and Inspections Required After a Collision: Service and Repair Safety Belt Procedure After
A Collision
SAFETY BELT PROCEDURE AFTER A COLLISION
WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must
be inspected by an authorized dealer to verify correct function:
- Retractors
- Buckles
- Belt tension sensor (BTS) (if equipped)
- Front safety belt buckle support assemblies (slide bar) (if equipped)
- Safety belt shoulder belt height adjusters (if equipped)
- Child safety seat tether bracket assemblies
- Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only)
If any safety belt assembly is damaged, does not operate correctly or does not pass all of the
Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be
installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal
must be restored to its original structural integrity and new safety belt assembly and attaching
hardware must be installed. Failure to install new safety belt assemblies and attaching hardware
may increase the risk of serious personal injury or death in a crash.
After any crash that results in deployment of the driver and/or front outboard passenger safety belt
pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors,
buckles and height adjusters) must be installed. Failure to install new safety belt systems increases
the risk of serious personal injury or death in a crash.
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 (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Adaptive Collapsible Steering Column > Component Information > Service
and Repair
Adaptive Collapsible Steering Column: Service and Repair
DEPLOYABLE STEERING COLUMN - IN-VEHICLE DEPLOYMENT
WARNING: Deploy all supplemental restraint system (SRS) devices (air bags, pretensioners, load
limiters, etc.) outdoors with all personnel at least 9.14 meters (30 feet) away to make sure of
personal safety. Due to the loud report which occurs when an SRS device is deployed, hearing
protection is required. Failure to follow these instructions may result in serious personal injury.
1. Depower the SRS.
2. NOTE: It may be necessary to lower or remove the deployable steering column from the
instrument panel to access the deployable steering
column electrical connector.
Access the deployable steering column electrical connector.
3. NOTE: If the deployable steering column does not have a hard-wired pigtail, it will be necessary
to cut the wires and connector(s) from the
vehicle wire harness and reconnect to the deployable steering column.
Cut each of the deployable steering column wires, leaving at least 4 inches to work with.
4. Remove any sheathing (if present) and strip the insulation from the ends of the cut wires. 5.
Make a jumper harness to deploy the deployable steering column.
- Obtain 2 wires (20 gauge minimum) at least 9.14 m (30 ft) long and strip both ends of each wire.
- At one end of the jumper harness, connect the wires together.
6. Using the end of the jumper harness that the wires are not connected together, attach each wire
of the jumper harness to each wire of the
deployable steering column. Use tape or other insulating material to make sure that the leads do
not make contact with each other.
7. Remain at least 9.14 m (30 ft) away from the deployable steering column. 8. From the end of the
jumper harness that is not connected to the deployable steering column, disconnect the 2 wires of
the jumper harness from
each other.
9. Deploy the deployable steering column by touching the ends of the 2 wires of the jumper
harness to the terminals of a 12-volt battery.
10. To allow for cooling, wait at least 10 minutes before approaching the deployed steering column.
11. Dispose of the deployed steering column in the same manner as any other part to be scrapped.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 eye protection when servicing a vehicle. Failure to follow this instruction may result in
serious personal injury.
- Never probe the electrical connectors on air bag, safety canopy or side air curtain modules.
Failure to follow this instruction may result in the accidental deployment of these modules, which
increases the risk of serious personal injury or death.
- 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 this
instruction may result in the accidental deployment of the safety canopy and cause serious
personal injury or death.
- To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to
follow this instruction may result in serious personal injury or death.
NOTE: The air bag warning indicator 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.
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 warning indicator for at least 30 seconds.
The air bag warning indicator will remain lit
continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning
indicator does not remain lit continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition switch to OFF.
6. WARNING: Always deplete the backup power supply before repairing or installing any new front
or side air bag supplemental restraint
system (SRS) component and before servicing, removing, installing, adjusting or striking
components near the front or side impact sensors or the restraints control module (RCM). Nearby
components include doors, instrument panel, console, door latches, strikers, seats and hood
latches.
Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and
impact sensor(s).
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Failure to follow these instructions may result in serious personal injury or death in the event of an
accidental deployment.
Disconnect the battery ground cable and wait at least one minute.
Repowering Procedure
1. Turn the ignition switch from OFF to ON. 2. Install RCM fuse 17 (10A) to the SJB and close the
cover.
3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of
any air bag module when the battery is
connected. Failure to follow these instructions may result in serious personal injury in the event of
an accidental deployment. Connect the
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7780
battery ground cable.
Connect the battery ground cable.
4. 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 warning indicator with the air bag modules installed. The air bag
warning indicator will light continuously for approximately 6 seconds and then turn off. If an SRS
fault is present, the air bag warning indicator will: fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag warning 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 warning 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 warning
indicator and any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the RCM and occupant classification system module (OCSM)
using a scan tool.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7781
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 eye protection when servicing a vehicle. Failure to follow this instruction may result in
serious personal injury.
- Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear
seam pointed away from the body. Do not set a live air bag module down with the deployment
door/trim cover/tear seam face down. Failure to follow these instructions may result in serious
personal injury in the event of an accidental deployment.
- Never probe the electrical connectors on air bag, safety canopy or side air curtain modules.
Failure to follow this instruction may result in the accidental deployment of these modules, which
increases the risk of serious personal injury or death.
- Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive
load limiting retractors. Failure to follow this instruction may result in the accidental deployment of
the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious
personal injury or death.
- 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.
- To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to
follow this instruction may result in serious personal injury or death.
NOTE: The air bag warning indicator 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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7782
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 warning indicator for at least 30 seconds.
The air bag warning indicator will remain lit
continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning
indicator does not remain lit continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: Always deplete the backup power supply before repairing or installing any new front
or side air bag supplemental restraint
system (SRS) component and before servicing, removing, installing, adjusting or striking
components near the front or side impact sensors or the restraints control module (RCM). Nearby
components include doors, instrument panel, console, door latches, strikers, seats and hood
latches.
Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and
impact sensor(s).
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Failure to follow these instructions may result in serious personal injury or death in the event of an
accidental deployment.
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.
9. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7783
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.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7784
15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat
side air bag module electrical connector.
Explorer and Mountaineer vehicles 16. Release and position aside the passenger side C-pillar trim
panel.
17. Disconnect the passenger side safety canopy module electrical connector.
18. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy module electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7785
19. Release and position aside the driver side C-pillar trim panel.
20. Disconnect the driver side safety canopy module electrical connector.
21. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy module electrical connector.
Explorer Sport Trac vehicles 22. Remove the driver and passenger side upper C-pillar trim panels.
23. Disconnect the passenger side safety canopy module electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7786
24. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy module electrical connector.
25. Disconnect the driver side safety canopy module electrical connector.
26. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy module electrical connector.
All vehicles 27. 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7787
28. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air
bag module electrical connector.
29. Install the RCM fuse 17 (10A) to the SJB. 30. 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. 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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7788
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.
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 10. Remove the restraint system diagnostic tool from the
vehicle harness side of the driver side safety canopy module electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7789
11. Connect the driver side safety canopy module electrical connector.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7790
15. Install the passenger side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
All vehicles 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7791
19. Connect the LH side passenger air bag module electrical connector.
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 driver air bag module electrical connectors are unique and cannot be reversed
when connected to 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. Damage to the connector or component
may occur.
Connect the driver air bag module electrical connectors as noted in removal.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7792
24. Install the 2 driver air bag module bolts (1 shown).
- Tighten to 7 Nm (62 lb-in).
25. 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.
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: Make sure no one is in the vehicle and there is nothing blocking or placed in front
of any air bag module when the battery is
connected. Failure to follow these instructions may result in serious personal injury in the event of
an accidental deployment.
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 warning indicator with the air bag modules installed. The air bag
warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag
SRS fault is present, the air bag warning indicator will: fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag warning 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 warning 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 warning
indicator and any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the RCM and occupant classification system module (OCSM)
using a scan tool.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Side Air
Bag Module, Left
View 151-28
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Side Air
Bag Module, Left > Page 7797
View 151-29
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Side Air
Bag Module, Left > Page 7798
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver
Air Bag Unit 1
C216A
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Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver
Air Bag Unit 1 > Page 7801
C216B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Air Bag Unit 1 > Page 7802
C367
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Air Bag Unit 1 > Page 7803
C337
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Air Bag Unit 1 > Page 7804
Air Bag: Diagrams
C216A
C216B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver
Air Bag Unit 1 > Page 7805
C367
C337
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Air Bag Unit 1 > Page 7806
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Air Bag Unit 1 > Page 7807
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Air Bag Unit 1 > Page 7808
C9006
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Air Bag Unit 1 > Page 7809
C3214
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver
Air Bag Unit 1 > Page 7810
C9007
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 and Installation
WARNING:
- Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result
in serious personal injury.
- Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear
seam pointed away from the body. Do not set a live air bag module down with the deployment
door/trim cover/tear seam face down. Failure to follow these instructions may result in serious
personal injury in the event of an accidental deployment.
- Never probe the electrical connectors on air bag, safety canopy or side air curtain modules.
Failure to follow this instruction may result in the accidental deployment of these modules, which
increases the risk of serious personal injury or death.
NOTE:
- The air bag warning indicator 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 SRS. 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 reversed when
connected to 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. Damage to the connector or component may
occur.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7813
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 driver air bag module.
4. To install, reverse the removal procedure. 5. Repower the SRS.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7814
Air Bag: Service and Repair Passenger Air Bag Module
PASSENGER AIR BAG MODULE
Removal and Installation
WARNING:
- Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result
in serious personal injury.
- Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear
seam pointed away from the body. Do not set a live air bag module down with the deployment
door/trim cover/tear seam face down. Failure to follow these instructions may result in serious
personal injury in the event of an accidental deployment.
- Never probe the electrical connectors on air bag, safety canopy or side air curtain modules.
Failure to follow this instruction may result in the accidental deployment of these modules, which
increases the risk of serious personal injury or death.
- Do not repaint air bag modules with discolored or damaged trim covers or deployment doors; new
air bag modules must be installed.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7815
Failure to follow this instruction may result in the air bag deploying incorrectly, which increases the
risk of serious personal injury or death in a crash.
NOTE:
- The air bag warning indicator 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 SRS. 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 passenger 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 doors. Damage to the air bag module
may occur.
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 SRS.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7816
Air Bag: Service and Repair Safety Canopy Module
SAFETY CANOPY MODULE
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7817
Part 2
Removal
WARNING:
- Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result
in serious personal injury.
- Always carry or place a live safety canopy, or side air curtain module, with the module and tear
seam pointed away from your body. Failure to follow this instruction may result in serious personal
injury or death in the event of an accidental deployment.
- Anytime the safety canopy or side air curtain module has deployed, a new headliner and new A-,
B-, C- and D-pillar upper trim panels and attaching hardware must be installed. Remove any other
damaged components and hardware and install new components and hardware as needed. Failure
to follow these instructions may result in the safety canopy or side air curtain module deploying
incorrectly and increases the risk of serious personal injury or death in a crash.
- When installing a new headliner on a vehicle equipped with safety canopy or side air curtain
modules, make sure the headliner has the word AIRBAG on the headliner where it meets each
B-pillar trim panel. Otherwise, you have the wrong headliner. Failure to follow this instruction may
result in the safety canopy or side air curtain module not deploying or deploying incorrectly,
increasing the risk of personal injury or death in a crash.
- Before installing a safety canopy or side air curtain module, inspect the roofline for any damage. If
necessary, the sheet metal must be reworked to its original condition and structural integrity. Install
new fasteners if damaged and remove foreign material. Failure to follow these instructions may
result in the safety canopy or side air curtain deploying incorrectly, which increases the risk of
serious personal injury or death in a crash.
- Inspect a safety canopy or side air curtain module before installation. If the module is damaged,
the cover has separated or the safety canopy/side air curtain material has been exposed, install a
new module. Do not attempt to repair the module. Failure to follow these instructions may result in
the safety canopy or side air curtain deploying incorrectly, which increases the risk of serious
personal injury or death in a crash.
- Do not obstruct or place objects in the deployment path of the safety canopy or side air curtain
module. Failure to follow this instruction may result in the safety canopy or side air curtain module
deploying incorrectly and increases the risk of serious personal injury or death in a crash.
- Never put any type of fastener or tie strap around any part of a safety canopy module, side air
curtain module or interior trim panel. This will prevent the safety canopy or side air curtain module
from deploying correctly. Failure to follow this instruction may increase the risk of serious personal
injury or death in a crash.
- Never probe the electrical connectors on air bag, safety canopy or side air curtain modules.
Failure to follow this instruction may result in the accidental deployment of these modules, which
increases the risk of serious personal injury or death.
- Always use new torque-prevailing type J-nuts when installing the safety canopy in the vehicle.
Use of these J-nuts is mandatory to reduce the risk of loss of fastener effectiveness. Failure to
follow this instruction may result in the safety canopy module deploying incorrectly and increases
the risk of serious personal injury or death in a crash.
NOTE:
- The air bag warning indicator 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.
- RH shown, LH similar.
All vehicles 1. Depower the SRS. 2. Remove the headliner.
Vehicles with auxiliary climate control
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7818
3. Remove the 2 retainers and the auxiliary climate control headliner duct from the C-pillar.
All vehicles
4. NOTE: Note the 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 moon roof
5. NOTE: Note the position of the 2 rear moon roof drain hose routing clips for installation.
Disconnect the rear moon roof drain tube and detach the 2 rear moon roof 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. 9. Remove
the safety canopy module front 2 bolts.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7819
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 or side air curtain module, inspect the roofline for any damage. If
necessary, the sheet metal must be reworked to its original condition and structural integrity. Install
new fasteners if damaged and remove foreign material. Failure to follow these instructions may
result in the safety canopy or side air curtain deploying incorrectly, which increases the risk of
serious personal injury or death in a crash.
- Inspect a safety canopy or side air curtain module before installation. If the module is damaged,
the cover has separated or the safety canopy/side air curtain material has been exposed, install a
new module. Do not attempt to repair the module. Failure to follow these instructions may result in
the safety canopy or side air curtain deploying incorrectly, which increases the risk of serious
personal injury or death in a crash.
- Never put any type of fastener or tie strap around any part of a safety canopy module, side air
curtain module or interior trim panel. This will prevent the safety canopy or side air curtain module
from deploying correctly. Failure to follow this instruction may increase the risk of serious personal
injury or death in a crash.
- Always use new torque-prevailing type J-nuts when installing the safety canopy in the vehicle.
Use of these J-nuts is mandatory to reduce the risk of loss of fastener effectiveness. Failure to
follow this instruction may result in the safety canopy module deploying incorrectly and increases
the risk of serious personal injury or death in a crash.
All vehicles 1. Remove the 4 front J-nuts and install new.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7820
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).
7. Install the 3 C-pillar safety canopy module bolts.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7821
- 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 moon roof
13. NOTE: Make sure to route the moon roof drain hose as noted during removal.
Connect the rear moon roof drain tube and attach the 2 rear moon roof 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 15. Install the auxiliary climate control headliner duct and 2
retainers to the C-pillar.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7822
All vehicles 16. Install the headliner. 17. Repower the SRS.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations
Air Bag Control Module: Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations > Page 7826
View 151-18
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations > Page 7827
View 151-21
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Diagrams > Driver Can Vent Unit
C216C
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Diagrams > Driver Can Vent Unit > Page 7830
Air Bag Control Module: Diagrams Restraints Control Module
C310A
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Diagrams > Driver Can Vent Unit > Page 7831
C310B (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Diagrams > Driver Can Vent Unit > Page 7832
C310B (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Diagrams > Page 7833
Air Bag Control Module: Service and Repair
RESTRAINTS CONTROL MODULE (RCM)
Special Tool(s)
Special Tool(s)
Removal
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 this
instruction may result in the accidental deployment of the safety canopy and cause serious
personal injury or death.
- If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact
sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the
original production configuration. A new RCM and sensors must be installed whether or not the air
bags have deployed. Failure to follow these instructions may result in serious personal injury or
death in a crash.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Diagrams > Page 7834
- Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if
equipped) to the specified torque. Failure to do so may result in incorrect restraint system
operation, which increases the risk of personal injury or death in a crash.
CAUTION: When installing a new RCM, it is necessary to carry out programmable module
installation (PMI). System failure may occur if PMI is not performed.
NOTE:
- When installing a new restraints control module (RCM), always make sure the correct RCM is
being installed. If an incorrect RCM is installed, erroneous DTCs will result.
- The air bag warning indicator 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. Carry out the steps necessary to prepare for programmable module installation (PMI). 2.
Depower the SRS. 3. Remove the front floor console. 4. Disconnect the large 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
1. Install the RCM. 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Diagrams > Page 7835
5. CAUTION: Putting the large restraints control module (RCM) electrical connector into the RCM
on an angle may cause bad electrical
connections and damage components.
Position the large RCM electrical connector into the RCM.
6. Connect the large RCM connector.
- CAUTION: Do not push the connector to the point where the lever pivots and seats itself. Light
pressure is needed to get the connector into position on the restraints control module (RCM),
before using the lever to fully seat the connector. Damage to the connector or component may
occur.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Diagrams > Page 7836
7. Install the front floor console. 8. Repower the SRS. Do not prove out the SRS at this time. 9.
Carry out the steps necessary to complete PMI.
10. 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 warning indicator with the air bag modules installed. The air bag
warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag
SRS fault is present, the air bag warning indicator will: fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag warning 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 warning 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 warning
indicator and any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the RCM and occupant classification system module (OCSM)
using a scan tool.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Indicator > Component Information
> Diagrams
C2286
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Indicator > Component Information
> Diagrams > Page 7840
Air Bag Deactivation Indicator: Service and Repair
PASSENGER AIR BAG DEACTIVATION (PAD) INDICATOR
Removal and Installation
NOTE:
- The air bag warning indicator 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 SRS. 2. Remove the floor console. 3. Gently pull outward to release the clips on
the instrument panel (I/P) center finish panel. 4. Disconnect the passenger air bag deactivation
(PAD) indicator electrical connector. 5. Remove the 2 screws and PAD indicator. 6. To install,
reverse the removal procedure. 7. Repower the SRS.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Diagrams
Clockspring Assembly / Spiral Cable: Diagrams
C218A
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Diagrams > Page 7844
C218B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Diagrams > Page 7845
Clockspring Assembly / Spiral Cable: Service and Repair
Clockspring
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Diagrams > Page 7846
Part 2
Removal
NOTE: The air bag warning indicator 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. Remove the driver air bag module. 2. Remove the steering wheel. 3. Remove the 2 screws and
the instrument panel (I/P) lower steering column opening cover. 4. Remove the 3 screws and the
lower steering column shroud. 5. Remove the upper steering column shroud. 6. Disconnect the
clockspring electrical connector. 7. Remove the 2 screws and position aside the steering wheel
rotation sensor. 8. Remove the 2 clockspring screws and remove the clockspring.
Installation
1. CAUTION: If installing a new clockspring, do not remove the clockspring anti-rotation key until
the steering wheel is installed. If the
anti-rotation key has been removed before installing the steering wheel, the clockspring must be
centered. Failure to follow this instruction may result in component damage and/or system failure.
Install the clockspring and the 2 screws.
2. Install the steering wheel rotation sensor and 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.
7. WARNING: If the clockspring is not correctly centralized, it may fail prematurely. If in doubt,
repeat the centralizing procedure.
Failure to follow these instructions may increase the risk of serious personal injury or death in a
crash.
CAUTION: To prevent component damage and/or system failure, when reusing a clockspring it must be
centered.
- Do not over-rotate the clockspring inner rotor. The internal ribbon wire is connected to the
clockspring rotor. The internal ribbon wire acts as a stop and can be broken from its internal
connection. Failure to follow this instruction may result in component damage and/or system
failure.
If a new clockspring was installed and the anti-rotation key has not been removed GO to Step 9.
If a new clockspring was installed and the anti-rotation key has been removed before the steering
wheel is installed or the same clockspring is being installed, rotate the clockspring inner rotor
counterclockwise and carefully feel for the ribbon wire to run out of length with slight resistance.
Stop rotating the clockspring inner rotor at this point.
8. Starting with the clockspring inner rotor, wiring and connector in the 12 o'clock position, rotate
the inner rotor clockwise through 2-1/2
revolutions to center the clockspring. The clockspring inner rotor, wiring and connector must be in the 12 o'clock position.
9. CAUTION: To prevent damage to the clockspring, make sure the road wheels are in the
straight-ahead position.
NOTE: The clockspring inner rotor, wiring and connector must be in the 12 o'clock position to install
the steering wheel.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Diagrams > Page 7847
Install the steering wheel.
10. If a new clockspring was installed, remove the anti-rotation key. 11. Install the driver air bag
module.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
Forward Crash Sensor
Impact Sensor: Locations Forward Crash Sensor
View 151-1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Forward Crash Sensor > Page 7853
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Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Forward Crash Sensor > Page 7854
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Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
Forward Crash Sensor > Page 7855
Impact Sensor: Locations Side Impact Sensor
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Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
Forward Crash Sensor > Page 7856
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Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Forward Crash Sensor > Page 7857
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Forward Crash Sensor > Page 7858
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Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Forward Crash Sensor > Page 7860
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Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams >
Forward Crash Sensor
Impact Sensor: Diagrams Forward Crash Sensor
C1465
C1466
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams >
Forward Crash Sensor > Page 7863
Impact Sensor: Diagrams Side Impact Sensor
C567A
C644A
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams >
Forward Crash Sensor > Page 7864
C3248
C3249
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Removal and Installation
WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the
impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting
areas to the original production configuration. A new RCM and sensors must be installed whether
or not the air bags have deployed. Failure to follow these instructions may result in serious
personal injury or death in a crash.
NOTE:
- The air bag warning indicator 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Front Impact Severity Sensor > Page 7867
- 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 SRS. 2. Remove the 4 pin-type retainers and the lower radiator air deflector. 3.
Disconnect the electrical connector.
4. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact
sensor (if equipped) to the specified torque.
Failure to do so may result in incorrect restraint system operation, which increases the risk of
personal injury or death in a crash.
NOTE: Make sure the radiator support and front impact severity sensor mating surfaces are clean
and free of foreign material.
Remove the bolt and sensor. To install, tighten to 12 Nm (9 lb-ft).
5. To install, reverse the removal procedure. 6. Repower the SRS.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Front Impact Severity Sensor > Page 7868
Impact Sensor: Service and Repair Side Impact Sensor - C-Pillar
SIDE IMPACT SENSOR - C-PILLAR
Removal and Installation
WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the
impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting
areas to the original production configuration. A new RCM and sensors must be installed whether
or not the air bags have deployed. Failure to follow these instructions may result in serious
personal injury or death in a crash.
NOTE:
- The air bag warning indicator 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.
- The LH and RH C-pillar mounted side impact sensors are not interchangeable.
1. Depower the SRS. 2. Remove the rear door scuff plate.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Front Impact Severity Sensor > Page 7869
3. Remove the bolt and 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 electrical connector.
7. 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 side impact sensor. To install, tighten to 12 Nm (9 lb-ft).
8. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact
sensor (if equipped) to the specified torque.
Failure to do so may result in incorrect restraint system operation, which increases the risk of
personal injury or death in a crash.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
To install, reverse the removal procedure.
9. Repower the SRS.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Front Impact Severity Sensor > Page 7870
Impact Sensor: Service and Repair Side Impact Sensor - Front Door
SIDE IMPACT SENSOR - FRONT DOOR
Removal and Installation
WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the
impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting
areas to the original production configuration. A new RCM and sensors must be installed whether
or not the air bags have deployed. Failure to follow these instructions may result in serious
personal injury or death in a crash.
NOTE:
- The air bag warning indicator 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.
- Driver side shown, passenger side similar.
1. Depower the SRS. 2. Remove the front interior door trim panel. 3. Detach the rearward lower
corner of the weathershield on the door to expose the side impact sensor. 4. Disconnect the side
impact sensor electrical connector.
5. 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Front Impact Severity Sensor > Page 7871
Remove the bolt and the side impact sensor. To install, tighten to 9 Nm (80 lb-in).
6. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact
sensor (if equipped) to the specified torque.
Failure to do so may result in incorrect restraint system operation, which increases the risk of
personal injury or death in a crash.
To install, reverse the removal procedure.
7. Repower the SRS.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag >
Component Information > Locations
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Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag >
Component Information > Locations > Page 7875
C3159
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag >
Component Information > Locations > Page 7876
Seat Occupant Classification Module - Air Bag: Service and Repair
OCCUPANT CLASSIFICATION SYSTEM MODULE (OCSM)
Removal and Installation
NOTE:
- The air bag warning indicator 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 seat similar.
- Seat is removed for clarity.
1. Depower the SRS. 2. From underneath the front of the seat, disconnect the occupant
classification system module (OCSM) electrical connector.
3. NOTE: Note the position of the locator tab on the OCSM for installation.
Remove the 2 screws and the OCSM. 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. 4. To install, reverse the removal procedure. 5. Repower the SRS. Do not prove out the SRS
at this time. 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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag >
Component Information > Locations > Page 7877
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/Occupant Classification
Sensor (OCS) System Reset
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Locations > Seat Pressure Sensor, Left
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Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Locations > Seat Pressure Sensor, Left > Page 7882
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Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Diagrams > Seat Pressure Sensor, Left
C3291
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Diagrams > Seat Pressure Sensor, Left > Page 7885
C3292
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Diagrams > Page 7886
Seat Occupant Sensor: Description and Operation
OCCUPANT CLASSIFICATION SENSOR (OCS) SYSTEM
The occupant classification sensor (OCS) system is standard equipment on all front passenger
seats. For information on diagnosing or servicing the OCS system, refer to Air Bag Systems.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Diagrams > Page 7887
Seat Occupant Sensor: Service and Repair
OCCUPANT CLASSIFICATION SENSOR
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Diagrams > Page 7888
Part 2
Removal
WARNING:
- The occupant classification sensor (OCS) rails have a built-in strain gauge which may operate
incorrectly if an OCS rail is dropped by itself, dropped after it is installed to the front passenger seat
or dropped after it is installed to a front passenger seat track assembly. Use care when handling an
OCS rail before or after it is installed to the front passenger seat or seat track assembly. Failure to
follow these instructions may result in incorrect operation of the OCS system and increases the risk
of serious personal injury or death in a crash.
- Do not disassemble the occupant classification sensor (OCS) rail or tighten or loosen any of the
nuts and bolts installed to the OCS rail body. Only the 8 bolts that attach the 2 OCS rails to the seat
track may be removed and installed. Failure to follow these instructions may result in incorrect
operation of the OCS system and increase the risk of serious personal injury or death in a crash.
- Never allow oil, grease, water or foreign contaminants to get on/in the occupant classification
sensor (OCS) components or electrical connectors. Failure to follow this instruction may result in
incorrect operation of the OCS system and increases the risk of serious personal injury or death in
a crash.
- Use care when handling the front passenger seat and track assembly. Dropping the assembly,
placing excessive weight on or sitting on a front passenger seat that is not secured in the vehicle
may result in damaged seat components. Failure to follow these instructions may result in incorrect
operation of the occupant classification sensor (OCS) system and increases the risk of serious
personal injury or death in a crash.
CAUTION: Prevent oil and/or grease from getting on the occupant classification sensor (OCS) rail
bolts as this can lead to tightening beyond the specified torque value. Failure to follow this
instruction may result in damaged or broken OCS rail bolts.
NOTE:
- The air bag warning indicator 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 shown, inboard similar.
1. Remove the passenger seat.
2. CAUTION: Before releasing the occupant classification sensor (OCS) rail electrical connector,
push only on the tip of the connector
release tab to release the electrical connector. Do not insert the tool too deep into the OCS rail
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Diagrams > Page 7889
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. 6. Move the seat to the rearward most
position.
- If equipped with a power seat track, apply power and ground to the pins shown.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Diagrams > Page 7890
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.
- To make sure of correct installation, the OCS rail bolts must be installed in the sequence shown.
1. WARNING: To prevent foreign material and contaminants from entering the occupant
classification sensor (OCS) rail, make sure the
OCS rail shield is present, is not damaged and is correctly installed to the OCS rail. Failure to
follow these instructions may result in incorrect operation of the OCS system and increases the risk
of serious personal injury or death in a crash.
CAUTION: Prevent oil and/or grease from getting on the OCS rail bolts as this can lead to
tightening beyond the specified torque value. Failure to follow this instruction may result in
damaged or broken OCS rail bolts.
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. 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).
3. While still holding the OCS rail and shield firmly in position, install the OCS rail front mounting
position front bolt.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Diagrams > Page 7891
- 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 frame.
- 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. 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, 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, carry out the Occupant Classification Sensor (OCS) System
Reset procedure and prove out the SRS. See: Service and Repair/Occupant Classification Sensor
(OCS) System Reset
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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:
- Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive
load limiting retractors. Failure to follow this instruction may result in the accidental deployment of
the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious
personal injury or death.
- Never probe the electrical connectors on air bag, safety canopy or side air curtain modules.
Failure to follow this instruction may result in the accidental deployment of these modules, which
increases the risk of serious personal injury or death.
NOTE:
- The air bag warning indicator 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 seat similar.
1. Position the front seat to the rearmost and upward position. 2. Depower the SRS. 3. Disconnect
the electrical connector.
4. WARNING: Always tighten the seat position sensor retaining bolt to specified torque. Failure to
do so may result in incorrect restraint
system operation, which increases the risk of personal injury or death in a crash.
NOTE: Note the position of the seat position sensor locating tab for installation.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information >
Service and Repair > Page 7895
Remove the bolt and seat position sensor. To install, tighten to 6 Nm (53 lb-in).
5. To install, reverse the removal procedure. 6. Repower the SRS.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair
Side Air Bag: Service and Repair
SIDE AIR BAG MODULE
Removal
WARNING:
- Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result
in serious personal injury.
- Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear
seam pointed away from the body. Do not set a live air bag module down with the deployment
door/trim cover/tear seam face down. Failure to follow these instructions may result in serious
personal injury in the event of an accidental deployment.
- Never probe the electrical connectors on air bag, safety canopy or side air curtain modules.
Failure to follow this instruction may result in the accidental deployment of these modules, which
increases the risk of serious personal injury or death.
- If the seat side air bag cover has been damaged or separated from its mounting, or if the air bag
material has been exposed, install a new seat side air bag module. Never try to repair the seat side
air bag module. Failure to follow these instructions may result in the seat side air bag deploying
incorrectly, which increases the risk of serious personal injury or death in a crash.
- Front seat backrest trim covers installed on seats equipped with seat side air bags cannot be
repaired. A new trim cover must be installed. Cleaning is permissible. Failure to follow these
instructions may result in the seat side air bag module deploying incorrectly and increase the risk of
serious personal injury or death in a crash.
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 module.
- The supplemental restraint system (SRS) must be fully operational and free of faults before
releasing the vehicle to the customer.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Page 7899
- 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 shown, passenger seat similar.
1. Remove the front seat and depower the SRS. 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 backrest trim covers installed on seats equipped with seat side air bags
cannot be repaired. A new trim cover
must be installed. Cleaning is permissible. Failure to follow these instructions may result in the seat
side air bag module deploying incorrectly and increase the risk of serious personal injury or death
in a crash.
CAUTION: Use care when separating the seat backrest trim cover from the hook-and-loop strips,
or the hook-and-loop strip can be torn from the seat backrest foam pad.
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.
7. Remove the first row of hog rings.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Page 7900
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 seat side air bag module and mounting surfaces for any damage or foreign material
before installing the seat side air bag module. If any damage is found, install new components. If
any foreign material is found, remove it. Failure to follow these instructions may result in the seat
side air bag module deploying incorrectly and increase the risk of serious personal injury or death
in a crash.
- Before installing the seat side air bag module/deployment chute assembly: Inspect the side air bag module and mounting surfaces for any damage or foreign material.
- Remove any foreign material from the mounting surfaces of the deployment chute, the seat
backrest frame mounting bracket and the air bag module cavity in the seat backrest foam pad.
- Install new parts if damaged.
Failure to follow these instructions may result in the seat side air bag deploying incorrectly, which
increases the risk of serious personal injury or death in a crash.
- If the seat side air bag cover has been damaged or separated from its mounting, or if the air bag
material has been exposed, install a new seat side air bag module. Never try to repair the seat side
air bag module. Failure to follow these instructions may result in the seat side air bag deploying
incorrectly, which increases the risk of serious personal injury or death in a crash.
CAUTION: Make sure the side air bag module wiring harness is not pinched between the side air
bag module and the backrest frame. Damage to the wire harness may occur.
All seats 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Page 7901
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 (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Page 7902
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 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 (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Child Seat > Component Information > Description and Operation
Child Seat: Description and Operation
ATTACHING SAFETY SEATS WITH TETHER STRAPS
Some manufacturers make child safety seats that include a tether strap that goes over the back of
the vehicle seat and attaches to an anchoring point. Other manufacturers offer the tether strap as
an accessory. Contact the manufacturer of the child safety seat for information about ordering a
tether strap.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations
Air Bag Control Module: Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 7910
View 151-18
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 7911
View 151-21
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Diagrams > Driver Can Vent Unit
C216C
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Diagrams > Driver Can Vent Unit > Page 7914
Air Bag Control Module: Diagrams Restraints Control Module
C310A
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Diagrams > Driver Can Vent Unit > Page 7915
C310B (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Diagrams > Driver Can Vent Unit > Page 7916
C310B (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Diagrams > Page 7917
Air Bag Control Module: Service and Repair
RESTRAINTS CONTROL MODULE (RCM)
Special Tool(s)
Special Tool(s)
Removal
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 this
instruction may result in the accidental deployment of the safety canopy and cause serious
personal injury or death.
- If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact
sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the
original production configuration. A new RCM and sensors must be installed whether or not the air
bags have deployed. Failure to follow these instructions may result in serious personal injury or
death in a crash.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Diagrams > Page 7918
- Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if
equipped) to the specified torque. Failure to do so may result in incorrect restraint system
operation, which increases the risk of personal injury or death in a crash.
CAUTION: When installing a new RCM, it is necessary to carry out programmable module
installation (PMI). System failure may occur if PMI is not performed.
NOTE:
- When installing a new restraints control module (RCM), always make sure the correct RCM is
being installed. If an incorrect RCM is installed, erroneous DTCs will result.
- The air bag warning indicator 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. Carry out the steps necessary to prepare for programmable module installation (PMI). 2.
Depower the SRS. 3. Remove the front floor console. 4. Disconnect the large 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
1. Install the RCM. 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Diagrams > Page 7919
5. CAUTION: Putting the large restraints control module (RCM) electrical connector into the RCM
on an angle may cause bad electrical
connections and damage components.
Position the large RCM electrical connector into the RCM.
6. Connect the large RCM connector.
- CAUTION: Do not push the connector to the point where the lever pivots and seats itself. Light
pressure is needed to get the connector into position on the restraints control module (RCM),
before using the lever to fully seat the connector. Damage to the connector or component may
occur.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Diagrams > Page 7920
7. Install the front floor console. 8. Repower the SRS. Do not prove out the SRS at this time. 9.
Carry out the steps necessary to complete PMI.
10. 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 warning indicator with the air bag modules installed. The air bag
warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag
SRS fault is present, the air bag warning indicator will: fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag warning 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 warning 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 warning
indicator and any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the RCM and occupant classification system module (OCSM)
using a scan tool.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification
Module - Air Bag > Component Information > Locations
View 151-29
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification
Module - Air Bag > Component Information > Locations > Page 7924
C3159
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification
Module - Air Bag > Component Information > Locations > Page 7925
Seat Occupant Classification Module - Air Bag: Service and Repair
OCCUPANT CLASSIFICATION SYSTEM MODULE (OCSM)
Removal and Installation
NOTE:
- The air bag warning indicator 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 seat similar.
- Seat is removed for clarity.
1. Depower the SRS. 2. From underneath the front of the seat, disconnect the occupant
classification system module (OCSM) electrical connector.
3. NOTE: Note the position of the locator tab on the OCSM for installation.
Remove the 2 screws and the OCSM. 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. 4. To install, reverse the removal procedure. 5. Repower the SRS. Do not prove out the SRS
at this time. 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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification
Module - Air Bag > Component Information > Locations > Page 7926
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/Occupant Classification Sensor (OCS) System Reset
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 eye protection when servicing a vehicle. Failure to follow this instruction may result in
serious personal injury.
- Never probe the electrical connectors on air bag, safety canopy or side air curtain modules.
Failure to follow this instruction may result in the accidental deployment of these modules, which
increases the risk of serious personal injury or death.
- 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 this
instruction may result in the accidental deployment of the safety canopy and cause serious
personal injury or death.
- To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to
follow this instruction may result in serious personal injury or death.
NOTE: The air bag warning indicator 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.
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 warning indicator for at least 30 seconds.
The air bag warning indicator will remain lit
continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning
indicator does not remain lit continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition switch to OFF.
6. WARNING: Always deplete the backup power supply before repairing or installing any new front
or side air bag supplemental restraint
system (SRS) component and before servicing, removing, installing, adjusting or striking
components near the front or side impact sensors or the restraints control module (RCM). Nearby
components include doors, instrument panel, console, door latches, strikers, seats and hood
latches.
Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and
impact sensor(s).
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Failure to follow these instructions may result in serious personal injury or death in the event of an
accidental deployment.
Disconnect the battery ground cable and wait at least one minute.
Repowering Procedure
1. Turn the ignition switch from OFF to ON. 2. Install RCM fuse 17 (10A) to the SJB and close the
cover.
3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of
any air bag module when the battery is
connected. Failure to follow these instructions may result in serious personal injury in the event of
an accidental deployment. Connect the
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7932
battery ground cable.
Connect the battery ground cable.
4. 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 warning indicator with the air bag modules installed. The air bag
warning indicator will light continuously for approximately 6 seconds and then turn off. If an SRS
fault is present, the air bag warning indicator will: fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag warning 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 warning 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 warning
indicator and any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the RCM and occupant classification system module (OCSM)
using a scan tool.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7933
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 eye protection when servicing a vehicle. Failure to follow this instruction may result in
serious personal injury.
- Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear
seam pointed away from the body. Do not set a live air bag module down with the deployment
door/trim cover/tear seam face down. Failure to follow these instructions may result in serious
personal injury in the event of an accidental deployment.
- Never probe the electrical connectors on air bag, safety canopy or side air curtain modules.
Failure to follow this instruction may result in the accidental deployment of these modules, which
increases the risk of serious personal injury or death.
- Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive
load limiting retractors. Failure to follow this instruction may result in the accidental deployment of
the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious
personal injury or death.
- 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.
- To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to
follow this instruction may result in serious personal injury or death.
NOTE: The air bag warning indicator 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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7934
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 warning indicator for at least 30 seconds.
The air bag warning indicator will remain lit
continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning
indicator does not remain lit continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: Always deplete the backup power supply before repairing or installing any new front
or side air bag supplemental restraint
system (SRS) component and before servicing, removing, installing, adjusting or striking
components near the front or side impact sensors or the restraints control module (RCM). Nearby
components include doors, instrument panel, console, door latches, strikers, seats and hood
latches.
Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and
impact sensor(s).
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Failure to follow these instructions may result in serious personal injury or death in the event of an
accidental deployment.
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.
9. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7935
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.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7936
15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat
side air bag module electrical connector.
Explorer and Mountaineer vehicles 16. Release and position aside the passenger side C-pillar trim
panel.
17. Disconnect the passenger side safety canopy module electrical connector.
18. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy module electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7937
19. Release and position aside the driver side C-pillar trim panel.
20. Disconnect the driver side safety canopy module electrical connector.
21. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy module electrical connector.
Explorer Sport Trac vehicles 22. Remove the driver and passenger side upper C-pillar trim panels.
23. Disconnect the passenger side safety canopy module electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7938
24. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy module electrical connector.
25. Disconnect the driver side safety canopy module electrical connector.
26. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy module electrical connector.
All vehicles 27. 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7939
28. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air
bag module electrical connector.
29. Install the RCM fuse 17 (10A) to the SJB. 30. 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. 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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7940
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.
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 10. Remove the restraint system diagnostic tool from the
vehicle harness side of the driver side safety canopy module electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7941
11. Connect the driver side safety canopy module electrical connector.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7942
15. Install the passenger side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
All vehicles 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7943
19. Connect the LH side passenger air bag module electrical connector.
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 driver air bag module electrical connectors are unique and cannot be reversed
when connected to 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. Damage to the connector or component
may occur.
Connect the driver air bag module electrical connectors as noted in removal.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7944
24. Install the 2 driver air bag module bolts (1 shown).
- Tighten to 7 Nm (62 lb-in).
25. 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.
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: Make sure no one is in the vehicle and there is nothing blocking or placed in front
of any air bag module when the battery is
connected. Failure to follow these instructions may result in serious personal injury in the event of
an accidental deployment.
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 warning indicator with the air bag modules installed. The air bag
warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag
SRS fault is present, the air bag warning indicator will: fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag warning 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 warning 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 warning
indicator and any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the RCM and occupant classification system module (OCSM)
using a scan tool.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
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 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 (V8-4.6L (2008))
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: After any crash, all of the following safety belt assemblies and attaching hardware must
be inspected by an authorized dealer to verify correct function:
- Retractors
- Buckles
- Belt tension sensor (BTS) (if equipped)
- Front safety belt buckle support assemblies (slide bar) (if equipped)
- Safety belt shoulder belt height adjusters (if equipped)
- Child safety seat tether bracket assemblies
- Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only)
If any safety belt assembly is damaged, does not operate correctly or does not pass all of the
Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be
installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal
must be restored to its original structural integrity and new safety belt assembly and attaching
hardware must be installed. Failure to install new safety belt assemblies and attaching hardware
may increase the risk of serious personal injury or death in a crash.
After any crash that results in deployment of the driver and/or front outboard passenger safety belt
pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors,
buckles and height adjusters) must be installed. Failure to install new safety belt systems increases
the risk of serious personal injury or death in a crash.
NOTE:
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7951
- 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 (V8-4.6L (2008))
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 7952
Child Seat Tether Attachment: Service and Repair Child Safety Seat Tether Anchor - Third Row
CHILD SAFETY SEAT TETHER ANCHOR - THIRD ROW
Part 1
Part 2
Removal and Installation
WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must
be inspected by an authorized dealer to verify correct function:
- Retractors
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 7953
- Buckles
- Belt tension sensor (BTS) (if equipped)
- Front safety belt buckle support assemblies (slide bar) (if equipped)
- Safety belt shoulder belt height adjusters (if equipped)
- Child safety seat tether bracket assemblies
- Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only)
If any safety belt assembly is damaged, does not operate correctly or does not pass all of the
Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be
installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal
must be restored to its original structural integrity and new safety belt assembly and attaching
hardware must be installed. Failure to install new safety belt assemblies and attaching hardware
may increase the risk of serious personal injury or death in a crash.
After any crash that results in deployment of the driver and/or front outboard passenger safety belt
pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors,
buckles and height adjusters) must be installed. Failure to install new safety belt systems increases
the risk of serious personal injury or death in a crash.
1. Remove the liftgate scuff plate trim panel. 2. Remove the tether anchor bolt(s) and tether
anchor(s).
- 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 (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Description and Operation
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 (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Description and Operation > Page 7957
Seat Belt Buckle: Testing and Inspection
FUNCTIONAL TEST - BUCKLE AND TONGUE
The safety belt buckle and tongue assembly must operate freely during the latching and unlatching
function. Fasten the safety belt by inserting the tongue (male portion) into the buckle (female
portion).
1. Verify the following during the latching sequence:
- Tongue insertion is not hindered by excessive effort.
- A "click" is heard when the buckle latches the tongue.
2. Verify the system integrity by forcefully pulling on the belt webbing. 3. Unlatch the belt by fully
depressing the buckle release button and allowing the belt to release and retract. 4. Verify the
following during the unlatching process:
- Push-button depression does not require excessive effort.
- Tongue can be removed easily from the buckle.
- Repeat the above steps 3 times.
5. If the inspection reveals an obvious concern(s) that can be readily identified, install a new safety
belt buckle or safety belt retractor assembly as
required. Do not attempt to carry out any repair on the buckle and tongue assembly. If a concern
still exists with either component, a new safety belt buckle or safety belt retractor assembly must
also be installed.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle
Seat Belt Buckle: Service and Repair Safety Belt Buckle
Safety Belt Buckle - Second Row, Bucket
SAFETY BELT BUCKLE - SECOND ROW, BUCKET
Removal and Installation
WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must
be inspected by an authorized dealer to verify correct function:
- Retractors
- Buckles
- Belt tension sensor (BTS) (if equipped)
- Front safety belt buckle support assemblies (slide bar) (if equipped)
- Safety belt shoulder belt height adjusters (if equipped)
- Child safety seat tether bracket assemblies
- Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only)
If any safety belt assembly is damaged, does not operate correctly or does not pass all of the
Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be
installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal
must be restored to its original structural integrity and new safety belt assembly and attaching
hardware must be installed. Failure to install new safety belt assemblies and attaching hardware
may increase the risk of serious personal injury or death in a crash.
After any crash that results in deployment of the driver and/or front outboard passenger safety belt
pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors,
buckles and height adjusters) must be installed. Failure to install new safety belt systems increases
the risk of serious personal injury or death in a crash.
1. Tilt the second row seat forward. 2. Remove the bolt and safety belt buckle.
- To install, tighten to 47 Nm (35 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle > Page 7960
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
Removal and Installation
WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must
be inspected by an authorized dealer to verify correct function:
- Retractors
- Buckles
- Belt tension sensor (BTS) (if equipped)
- Front safety belt buckle support assemblies (slide bar) (if equipped)
- Safety belt shoulder belt height adjusters (if equipped)
- Child safety seat tether bracket assemblies
- Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only)
If any safety belt assembly is damaged, does not operate correctly or does not pass all of the
Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be
installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal
must be restored to its original structural integrity and new safety belt assembly and attaching
hardware must be installed. Failure to install new safety belt assemblies and attaching hardware
may increase the risk of serious personal injury or death in a crash.
After any crash that results in deployment of the driver and/or front outboard passenger safety belt
pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors,
buckles and height adjusters) must be installed. Failure to install new safety belt systems increases
the risk of serious personal injury or death in a crash.
NOTE: Seat cushion removed for clarity.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle > Page 7961
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
SAFETY BELT BUCKLE - SECOND ROW, CENTER AND RH, 60/40, E-Z ENTRY
Removal and Installation
WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must
be inspected by an authorized dealer to verify correct function:
- Retractors
- Buckles
- Belt tension sensor (BTS) (if equipped)
- Front safety belt buckle support assemblies (slide bar) (if equipped)
- Safety belt shoulder belt height adjusters (if equipped)
- Child safety seat tether bracket assemblies
- Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only)
If any safety belt assembly is damaged, does not operate correctly or does not pass all of the
Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be
installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal
must be restored to its original structural integrity and new safety belt assembly and attaching
hardware must be installed. Failure to install new safety belt assemblies and attaching hardware
may increase the risk of serious personal injury or death in a crash.
After any crash that results in deployment of the driver and/or front outboard passenger safety belt
pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors,
buckles and height adjusters) must be installed. Failure to install new safety belt systems increases
the risk of serious personal injury or death in a crash.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle > Page 7962
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
Removal and Installation
WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must
be inspected by an authorized dealer to verify correct function:
- Retractors
- Buckles
- Belt tension sensor (BTS) (if equipped)
- Front safety belt buckle support assemblies (slide bar) (if equipped)
- Safety belt shoulder belt height adjusters (if equipped)
- Child safety seat tether bracket assemblies
- Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only)
If any safety belt assembly is damaged, does not operate correctly or does not pass all of the
Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be
installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal
must be restored to its original structural integrity and new safety belt assembly and attaching
hardware must be installed. Failure to install new safety belt assemblies and attaching hardware
may increase the risk of serious personal injury or death in a crash.
After any crash that results in deployment of the driver and/or front outboard passenger safety belt
pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors,
buckles and height adjusters) must be installed. Failure to install new safety belt systems increases
the risk of serious personal injury or death in a crash.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle > Page 7963
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
Removal and Installation
WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must
be inspected by an authorized dealer to verify correct function:
- Retractors
- Buckles
- Belt tension sensor (BTS) (if equipped)
- Front safety belt buckle support assemblies (slide bar) (if equipped)
- Safety belt shoulder belt height adjusters (if equipped)
- Child safety seat tether bracket assemblies
- Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only)
If any safety belt assembly is damaged, does not operate correctly or does not pass all of the
Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be
installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal
must be restored to its original structural integrity and new safety belt assembly and attaching
hardware must be installed. Failure to install new safety belt assemblies and attaching hardware
may increase the risk of serious personal injury or death in a crash.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle > Page 7964
After any crash that results in deployment of the driver and/or front outboard passenger safety belt
pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors,
buckles and height adjusters) must be installed. Failure to install new safety belt systems increases
the risk of serious personal injury or death in a crash.
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
Removal and Installation
WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must
be inspected by an authorized dealer to verify correct function:
- Retractors
- Buckles
- Belt tension sensor (BTS) (if equipped)
- Front safety belt buckle support assemblies (slide bar) (if equipped)
- Safety belt shoulder belt height adjusters (if equipped)
- Child safety seat tether bracket assemblies
- Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only)
If any safety belt assembly is damaged, does not operate correctly or does not pass all of the
Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be
installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal
must be restored to its original structural integrity and new safety belt assembly and attaching
hardware must be installed. Failure to install new safety belt assemblies and attaching hardware
may increase the risk of serious personal injury or death in a crash.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle > Page 7965
After any crash that results in deployment of the driver and/or front outboard passenger safety belt
pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors,
buckles and height adjusters) must be installed. Failure to install new safety belt systems increases
the risk of serious personal injury or death in a crash.
NOTE: Power seat shown, manual seat 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle > Page 7966
Seat Belt Buckle: Service and Repair Safety Belt Buckle and Pretensioner
SAFETY BELT BUCKLE AND PRETENSIONER
Removal and Installation
WARNING:
- Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result
in serious personal injury.
- After any crash, all of the following safety belt assemblies and attaching hardware must be
inspected by an authorized dealer to verify correct function: Retractors
- Buckles
- Belt tension sensor (BTS) (if equipped)
- Front safety belt buckle support assemblies (slide bar) (if equipped)
- Safety belt shoulder belt height adjusters (if equipped)
- Child safety seat tether bracket assemblies
- Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only)
If any safety belt assembly is damaged, does not operate correctly or does not pass all of the
Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be
installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal
must be restored to its original structural integrity and new safety belt assembly and attaching
hardware must be installed. Failure to install new safety belt assemblies and attaching hardware
may increase the risk of serious personal injury or death in a crash.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle > Page 7967
After any crash that results in deployment of the driver and/or front outboard passenger safety belt
pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors,
buckles and height adjusters) must be installed. Failure to install new safety belt systems increases
the risk of serious personal injury or death in a crash.
NOTE:
- The air bag warning indicator 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.
- 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.
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 (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information >
Locations > Safety Belt Buckle Switch, Passenger
View 151-29
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information >
Locations > Safety Belt Buckle Switch, Passenger > Page 7972
View 151-28
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information >
Diagrams > Safety Belt Buckle Switch, Driver > Page 7975
C3066
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information >
Description and Operation
Seat Belt Extension: 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 (V8-4.6L (2008))
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: After any crash, all of the following safety belt assemblies and attaching hardware must
be inspected by an authorized dealer to verify correct function:
- Retractors
- Buckles
- Belt tension sensor (BTS) (if equipped)
- Front safety belt buckle support assemblies (slide bar) (if equipped)
- Safety belt shoulder belt height adjusters (if equipped)
- Child safety seat tether bracket assemblies
- Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only)
If any safety belt assembly is damaged, does not operate correctly or does not pass all of the
Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be
installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal
must be restored to its original structural integrity and new safety belt assembly and attaching
hardware must be installed. Failure to install new safety belt assemblies and attaching hardware
may increase the risk of serious personal injury or death in a crash.
After any crash that results in deployment of the driver and/or front outboard passenger safety belt
pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors,
buckles and height adjusters) must be installed. Failure to install new safety belt systems increases
the risk of serious personal injury or death in a crash.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information >
Service and Repair > Page 7982
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).
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 (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information
> Description and Operation
Seat Belt Reminder Buzzer: 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(R)
The Belt-Minder(R) 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 indicator in
the instrument cluster.
To activate or deactivate the Belt-Minder(R) feature, refer to Instrument Panel, Gauges and
Warning Indicators or the Owner's Literature.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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(R)
The Belt-Minder(R) 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 indicator in
the instrument cluster.
To activate or deactivate the Belt-Minder(R) feature, refer to Instrument Panel, Gauges and
Warning Indicators or the Owner's Literature.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Description and Operation
Seat Belt Retractor: Description and Operation
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 restraints control module (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
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 (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Description and Operation > Page 7992
Seat Belt Retractor: Testing and Inspection
Functional Test - Retractor
The safety belt retractor assembly must be freely operational for extraction and retraction of the
safety belt webbing between full extension and in-vehicle stowed positions.
1. Extract and retract the safety belt between the full extension and stowed positions. 2. Verify the
retractor operates without excessive effort or binding. 3. Install a new safety belt retractor and
buckle if no obvious concerns are noticed and the complaint has been verified.
Functional Test - Automatic Locking Retractor
WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must
be inspected by an authorized dealer to verify correct function: Retractors
- Buckles
- Belt tension sensor (BTS) (if equipped)
- Front safety belt buckle support assemblies (slide bar) (if equipped)
- Safety belt shoulder belt height adjusters (if equipped)
- Child safety seat tether bracket assemblies
- Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only)
If any safety belt assembly is damaged, does not operate correctly or does not pass all of the
Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be
installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal
must be restored to its original structural integrity and new safety belt assembly and attaching
hardware must be installed. Failure to install new safety belt assemblies and attaching hardware
may increase the risk of serious personal injury or death in a crash.
After any crash that results in deployment of the driver and/or front outboard passenger safety belt
pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors,
buckles and height adjusters) must be installed. Failure to install new safety belt systems increases
the risk of serious personal injury or death in a crash.
1. Position the seat back into the full up position. 2. Position the height adjuster (if equipped) in the
full down or up position. 3. Latch the seat belt buckle and tongue assembly. 4. Pull the shoulder
belt out until the automatic locking retractor (ALR) feature is activated. 5. Release the shoulder belt
and allow it to retract until it stops. 6. Pull on the shoulder belt to check that the belt has remained
in the ALR mode. If the belt is not locked, install a new safety belt assembly. 7. Unlatch the safety
belt tongue from the buckle and allow the safety belt to retract to its stowed position. 8. Pull the
shoulder belt to verify the retractor assembly has converted automatically out of the ALR mode. If
the shoulder belt remains locked in the
stowed position, install a new safety belt retractor assembly.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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: After any crash, all of the following safety belt assemblies and attaching hardware must
be inspected by an authorized dealer to verify correct function:
- Retractors
- Buckles
- Belt tension sensor (BTS) (if equipped)
- Front safety belt buckle support assemblies (slide bar) (if equipped)
- Safety belt shoulder belt height adjusters (if equipped)
- Child safety seat tether bracket assemblies
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Safety Belt Retractor - Front > Page 7995
- Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only)
If any safety belt assembly is damaged, does not operate correctly or does not pass all of the
Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be
installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal
must be restored to its original structural integrity and new safety belt assembly and attaching
hardware must be installed. Failure to install new safety belt assemblies and attaching hardware
may increase the risk of serious personal injury or death in a crash.
After any crash that results in deployment of the driver and/or front outboard passenger safety belt
pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors,
buckles and height adjusters) must be installed. Failure to install new safety belt systems increases
the risk of serious personal injury or death in a crash.
NOTE:
- The air bag warning indicator 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 (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Safety Belt Retractor - Front > Page 7996
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: After any crash, all of the following safety belt assemblies and attaching hardware must
be inspected by an authorized dealer to verify correct function:
- Retractors
- Buckles
- Belt tension sensor (BTS) (if equipped)
- Front safety belt buckle support assemblies (slide bar) (if equipped)
- Safety belt shoulder belt height adjusters (if equipped)
- Child safety seat tether bracket assemblies
- Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only)
If any safety belt assembly is damaged, does not operate correctly or does not pass all of the
Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be
installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal
must be restored to its original structural integrity and new safety belt assembly and attaching
hardware must be installed. Failure to install new safety belt assemblies and attaching hardware
may increase the risk of serious personal injury or death in a crash.
After any crash that results in deployment of the driver and/or front outboard passenger safety belt
pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors,
buckles and height adjusters) must be installed. Failure to install new safety belt systems increases
the risk of serious personal injury or death in a crash.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Safety Belt Retractor - Front > Page 7997
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).
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 (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Safety Belt Retractor - Front > Page 7998
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: After any crash, all of the following safety belt assemblies and attaching hardware must
be inspected by an authorized dealer to verify correct function:
- Retractors
- Buckles
- Belt tension sensor (BTS) (if equipped)
- Front safety belt buckle support assemblies (slide bar) (if equipped)
- Safety belt shoulder belt height adjusters (if equipped)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Safety Belt Retractor - Front > Page 7999
- Child safety seat tether bracket assemblies
- Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only)
If any safety belt assembly is damaged, does not operate correctly or does not pass all of the
Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be
installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal
must be restored to its original structural integrity and new safety belt assembly and attaching
hardware must be installed. Failure to install new safety belt assemblies and attaching hardware
may increase the risk of serious personal injury or death in a crash.
After any crash that results in deployment of the driver and/or front outboard passenger safety belt
pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors,
buckles and height adjusters) must be installed. Failure to install new safety belt systems increases
the risk of serious personal injury or death in a crash.
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 (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Safety Belt Retractor - Front > Page 8000
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 (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Safety Belt Retractor - Front > Page 8001
Explorer Sport Trac
Removal and Installation
WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must
be inspected by an authorized dealer to verify correct function:
- Retractors
- Buckles
- Belt tension sensor (BTS) (if equipped)
- Front safety belt buckle support assemblies (slide bar) (if equipped)
- Safety belt shoulder belt height adjusters (if equipped)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Safety Belt Retractor - Front > Page 8002
- Child safety seat tether bracket assemblies
- Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only)
If any safety belt assembly is damaged, does not operate correctly or does not pass all of the
Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be
installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal
must be restored to its original structural integrity and new safety belt assembly and attaching
hardware must be installed. Failure to install new safety belt assemblies and attaching hardware
may increase the risk of serious personal injury or death in a crash.
After any crash that results in deployment of the driver and/or front outboard passenger safety belt
pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors,
buckles and height adjusters) must be installed. Failure to install new safety belt systems increases
the risk of serious personal injury or death in a crash.
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 (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Safety Belt Retractor - Front > Page 8003
Seat Belt Retractor: Service and Repair Safety Belt Retractor - Third Row
SAFETY BELT RETRACTOR - THIRD ROW
Removal and Installation
WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must
be inspected by an authorized dealer to verify correct function:
- Retractors
- Buckles
- Belt tension sensor (BTS) (if equipped)
- Front safety belt buckle support assemblies (slide bar) (if equipped)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Safety Belt Retractor - Front > Page 8004
- Safety belt shoulder belt height adjusters (if equipped)
- Child safety seat tether bracket assemblies
- Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only)
If any safety belt assembly is damaged, does not operate correctly or does not pass all of the
Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be
installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal
must be restored to its original structural integrity and new safety belt assembly and attaching
hardware must be installed. Failure to install new safety belt assemblies and attaching hardware
may increase the risk of serious personal injury or death in a crash.
After any crash that results in deployment of the driver and/or front outboard passenger safety belt
pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors,
buckles and height adjusters) must be installed. Failure to install new safety belt systems increases
the risk of serious personal injury or death in a crash.
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Diagrams > Driver Safety Belt Retractor Pretensioner > Page 8009
C2351
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Diagrams > Driver Safety Belt Retractor Pretensioner > Page 8010
C303
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Diagrams > Driver Safety Belt Retractor Pretensioner > Page 8011
C3201
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Diagrams > Driver Safety Belt Retractor Pretensioner > Page 8012
C3202
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Diagrams > Page 8013
Seat Belt Tensioner: 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 (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Diagrams > Page 8014
Seat Belt Tensioner: Service and Repair
SAFETY BELT BUCKLE AND PRETENSIONER
Removal and Installation
WARNING:
- Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result
in serious personal injury.
- After any crash, all of the following safety belt assemblies and attaching hardware must be
inspected by an authorized dealer to verify correct function: Retractors
- Buckles
- Belt tension sensor (BTS) (if equipped)
- Front safety belt buckle support assemblies (slide bar) (if equipped)
- Safety belt shoulder belt height adjusters (if equipped)
- Child safety seat tether bracket assemblies
- Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only)
If any safety belt assembly is damaged, does not operate correctly or does not pass all of the
Functional Tests in the Diagnosis and Testing portion, a new safety belt assembly must be
installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal
must be restored to its original structural integrity and new safety belt assembly and attaching
hardware must be installed. Failure to install new safety belt assemblies and attaching hardware
may increase the risk of serious personal injury or death in a crash.
After any crash that results in deployment of the driver and/or front outboard passenger safety belt
pretensioners, new driver and/or front
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Diagrams > Page 8015
outboard passenger safety belt systems (including retractors, buckles and height adjusters) must
be installed. Failure to install new safety belt systems increases the risk of serious personal injury
or death in a crash.
NOTE:
- The air bag warning indicator 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.
- 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.
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 (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information >
Locations
View 151-28
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information >
Locations > Page 8019
C356
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > Forward Crash Sensor
Impact Sensor: Locations Forward Crash Sensor
View 151-1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > Forward Crash Sensor > Page 8025
View 151-4
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > Forward Crash Sensor > Page 8026
View 151-1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > Forward Crash Sensor > Page 8027
View 151-4
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > Forward Crash Sensor > Page 8028
Impact Sensor: Locations Side Impact Sensor
View 151-22
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > Forward Crash Sensor > Page 8029
View 151-23
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > Forward Crash Sensor > Page 8030
View 151-24
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > Forward Crash Sensor > Page 8031
View 151-25
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > Forward Crash Sensor > Page 8032
View 151-31
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > Forward Crash Sensor > Page 8033
View 151-32
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Diagrams > Forward Crash Sensor
Impact Sensor: Diagrams Forward Crash Sensor
C1465
C1466
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Diagrams > Forward Crash Sensor > Page 8036
Impact Sensor: Diagrams Side Impact Sensor
C567A
C644A
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Diagrams > Forward Crash Sensor > Page 8037
C3248
C3249
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Removal and Installation
WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the
impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting
areas to the original production configuration. A new RCM and sensors must be installed whether
or not the air bags have deployed. Failure to follow these instructions may result in serious
personal injury or death in a crash.
NOTE:
- The air bag warning indicator 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Front Impact Severity Sensor > Page 8040
- 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 SRS. 2. Remove the 4 pin-type retainers and the lower radiator air deflector. 3.
Disconnect the electrical connector.
4. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact
sensor (if equipped) to the specified torque.
Failure to do so may result in incorrect restraint system operation, which increases the risk of
personal injury or death in a crash.
NOTE: Make sure the radiator support and front impact severity sensor mating surfaces are clean
and free of foreign material.
Remove the bolt and sensor. To install, tighten to 12 Nm (9 lb-ft).
5. To install, reverse the removal procedure. 6. Repower the SRS.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Front Impact Severity Sensor > Page 8041
Impact Sensor: Service and Repair Side Impact Sensor - C-Pillar
SIDE IMPACT SENSOR - C-PILLAR
Removal and Installation
WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the
impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting
areas to the original production configuration. A new RCM and sensors must be installed whether
or not the air bags have deployed. Failure to follow these instructions may result in serious
personal injury or death in a crash.
NOTE:
- The air bag warning indicator 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.
- The LH and RH C-pillar mounted side impact sensors are not interchangeable.
1. Depower the SRS. 2. Remove the rear door scuff plate.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Front Impact Severity Sensor > Page 8042
3. Remove the bolt and 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 electrical connector.
7. 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 side impact sensor. To install, tighten to 12 Nm (9 lb-ft).
8. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact
sensor (if equipped) to the specified torque.
Failure to do so may result in incorrect restraint system operation, which increases the risk of
personal injury or death in a crash.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
To install, reverse the removal procedure.
9. Repower the SRS.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Front Impact Severity Sensor > Page 8043
Impact Sensor: Service and Repair Side Impact Sensor - Front Door
SIDE IMPACT SENSOR - FRONT DOOR
Removal and Installation
WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the
impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting
areas to the original production configuration. A new RCM and sensors must be installed whether
or not the air bags have deployed. Failure to follow these instructions may result in serious
personal injury or death in a crash.
NOTE:
- The air bag warning indicator 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.
- Driver side shown, passenger side similar.
1. Depower the SRS. 2. Remove the front interior door trim panel. 3. Detach the rearward lower
corner of the weathershield on the door to expose the side impact sensor. 4. Disconnect the side
impact sensor electrical connector.
5. 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Front Impact Severity Sensor > Page 8044
Remove the bolt and the side impact sensor. To install, tighten to 9 Nm (80 lb-in).
6. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact
sensor (if equipped) to the specified torque.
Failure to do so may result in incorrect restraint system operation, which increases the risk of
personal injury or death in a crash.
To install, reverse the removal procedure.
7. Repower the SRS.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Locations > Safety Belt Buckle Switch, Passenger
View 151-29
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Locations > Safety Belt Buckle Switch, Passenger > Page 8049
View 151-28
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Diagrams > Safety Belt Buckle Switch, Driver > Page 8052
C3066
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Locations > Seat Pressure Sensor, Left
View 151-29
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Locations > Seat Pressure Sensor, Left > Page 8057
View 151-29
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Diagrams > Seat Pressure Sensor, Left
C3291
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Diagrams > Seat Pressure Sensor, Left > Page 8060
C3292
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Diagrams > Page 8061
Seat Occupant Sensor: Description and Operation
OCCUPANT CLASSIFICATION SENSOR (OCS) SYSTEM
The occupant classification sensor (OCS) system is standard equipment on all front passenger
seats. For information on diagnosing or servicing the OCS system, refer to Air Bag Systems.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Diagrams > Page 8062
Seat Occupant Sensor: Service and Repair
OCCUPANT CLASSIFICATION SENSOR
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Diagrams > Page 8063
Part 2
Removal
WARNING:
- The occupant classification sensor (OCS) rails have a built-in strain gauge which may operate
incorrectly if an OCS rail is dropped by itself, dropped after it is installed to the front passenger seat
or dropped after it is installed to a front passenger seat track assembly. Use care when handling an
OCS rail before or after it is installed to the front passenger seat or seat track assembly. Failure to
follow these instructions may result in incorrect operation of the OCS system and increases the risk
of serious personal injury or death in a crash.
- Do not disassemble the occupant classification sensor (OCS) rail or tighten or loosen any of the
nuts and bolts installed to the OCS rail body. Only the 8 bolts that attach the 2 OCS rails to the seat
track may be removed and installed. Failure to follow these instructions may result in incorrect
operation of the OCS system and increase the risk of serious personal injury or death in a crash.
- Never allow oil, grease, water or foreign contaminants to get on/in the occupant classification
sensor (OCS) components or electrical connectors. Failure to follow this instruction may result in
incorrect operation of the OCS system and increases the risk of serious personal injury or death in
a crash.
- Use care when handling the front passenger seat and track assembly. Dropping the assembly,
placing excessive weight on or sitting on a front passenger seat that is not secured in the vehicle
may result in damaged seat components. Failure to follow these instructions may result in incorrect
operation of the occupant classification sensor (OCS) system and increases the risk of serious
personal injury or death in a crash.
CAUTION: Prevent oil and/or grease from getting on the occupant classification sensor (OCS) rail
bolts as this can lead to tightening beyond the specified torque value. Failure to follow this
instruction may result in damaged or broken OCS rail bolts.
NOTE:
- The air bag warning indicator 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 shown, inboard similar.
1. Remove the passenger seat.
2. CAUTION: Before releasing the occupant classification sensor (OCS) rail electrical connector,
push only on the tip of the connector
release tab to release the electrical connector. Do not insert the tool too deep into the OCS rail
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Diagrams > Page 8064
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. 6. Move the seat to the rearward most
position.
- If equipped with a power seat track, apply power and ground to the pins shown.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Diagrams > Page 8065
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.
- To make sure of correct installation, the OCS rail bolts must be installed in the sequence shown.
1. WARNING: To prevent foreign material and contaminants from entering the occupant
classification sensor (OCS) rail, make sure the
OCS rail shield is present, is not damaged and is correctly installed to the OCS rail. Failure to
follow these instructions may result in incorrect operation of the OCS system and increases the risk
of serious personal injury or death in a crash.
CAUTION: Prevent oil and/or grease from getting on the OCS rail bolts as this can lead to
tightening beyond the specified torque value. Failure to follow this instruction may result in
damaged or broken OCS rail bolts.
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. 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).
3. While still holding the OCS rail and shield firmly in position, install the OCS rail front mounting
position front bolt.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Diagrams > Page 8066
- 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 frame.
- 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. 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, 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, carry out the Occupant Classification Sensor (OCS) System
Reset procedure and prove out the SRS. See: Air Bag Systems/Service and Repair/Occupant
Classification Sensor (OCS) System Reset
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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:
- Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive
load limiting retractors. Failure to follow this instruction may result in the accidental deployment of
the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious
personal injury or death.
- Never probe the electrical connectors on air bag, safety canopy or side air curtain modules.
Failure to follow this instruction may result in the accidental deployment of these modules, which
increases the risk of serious personal injury or death.
NOTE:
- The air bag warning indicator 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 seat similar.
1. Position the front seat to the rearmost and upward position. 2. Depower the SRS. 3. Disconnect
the electrical connector.
4. WARNING: Always tighten the seat position sensor retaining bolt to specified torque. Failure to
do so may result in incorrect restraint
system operation, which increases the risk of personal injury or death in a crash.
NOTE: Note the position of the seat position sensor locating tab for installation.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor >
Component Information > Service and Repair > Page 8070
Remove the bolt and seat position sensor. To install, tighten to 6 Nm (53 lb-in).
5. To install, reverse the removal procedure. 6. Repower the SRS.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Locations
View 151-28
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Locations > Page 8074
C356
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay >
Component Information > Locations > Page 8080
Accessory Delay Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair
> Antenna
Antenna: Service and Repair Antenna
ANTENNA
Removal and Installation
1. NOTE: To access the antenna cable-to-antenna lead-in cable connection, lower the glove
compartment door.
Disconnect the antenna cable from the antenna lead-in cable and release the pin-type retainers.
2. Remove the RH cowl side trim panel and the RH front door scuff plate trim panel. 3. Remove the
antenna mast and the antenna mast stanchion. 4. Remove the RH fender splash shield. 5. Release
the antenna cable grommet. 6. Remove the antenna cable bracket bolt and the antenna cable
assembly.
- To install, tighten to 8 Nm (71 lb-in).
7. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair
> Antenna > Page 8085
Antenna: Service and Repair Antenna - Satellite Radio
ANTENNA - SATELLITE RADIO
Removal and Installation
1. Remove the RH A-pillar trim panel. 2. Remove the 3 screws, the RH sun visor retaining clip, and
the RH sun visor.
- If equipped, disconnect the electrical connector.
3. Lower the front of the headliner enough to gain access to the satellite radio antenna electrical
connector.
4. NOTE: Remove the satellite antenna and pigtail through the mounting opening in the roof panel.
Remove the satellite antenna. -
Disconnect the electrical connector.
- Loosen the antenna bolt. To install, tighten to 5 Nm (44 lb-in).
- Compress the tabs and release the satellite antenna from the roof panel.
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair
> Antenna > Page 8086
Antenna: 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 (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair
> Antenna > Page 8087
Antenna: Service and Repair Antenna Lead-In Cable
ANTENNA LEAD-IN CABLE
Removal and Installation
1. Remove the audio control module (ACM). 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 (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair
> Antenna > Page 8088
Antenna: Service and Repair Global Positioning System (GPS) Antenna
GLOBAL POSITIONING SYSTEM (GPS) ANTENNA
Removal and Installation
NOTE: This procedure is the same as the satellite radio antenna procedure, as a combination
satellite radio/GPS is utilized for vehicles with navigation.
1. Remove the RH A-pillar trim panel. 2. Remove the 3 screws, the RH sun visor retaining clip, and
the RH sun visor.
- If equipped, disconnect the electrical connector.
3. Lower the front of the headliner enough to gain access to the GPS antenna electrical connector.
4. NOTE: Remove the GPS antenna and pigtail through the mounting opening in the roof panel.
Remove the GPS antenna. Disconnect the electrical connector.
- Loosen the antenna bolt. To install, tighten to 5 Nm (44 lb-in).
- Compress the tabs and release the GPS antenna from the roof panel.
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 opening 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 (IC) again.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transmitter
> Component Information > Service and Repair > Page 8093
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System
Transponder > Component Information > Diagrams
C2007
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Key-Pad > Component Information > Locations
View 151-31
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Key-Pad > Component Information > Locations > Page 8101
C500
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Key-Pad > Component Information > Locations > Page 8102
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 3 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 (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Key-Pad > Component Information > Locations > Page 8103
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 (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Transmitter > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Transmitter:
> 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate
Keyless Entry Transmitter: Customer Interest Keyless Entry - Transmitter May Not Operate
TSB 08-12-9
06/23/08
INOPERATIVE RKE TRANSMITTER (KEY FOB) - DISCHARGED KEY FOB BATTERY
FORD: 2008 Crown Victoria, Focus, Mustang 2007-2008 F-150 2008 E-Series, Expedition,
Explorer Sport Trac, Explorer, F-Super Duty, Ranger
LINCOLN: 2007-2008 Mark LT
MERCURY: 2008 Grand Marquis, Mountaineer
ISSUE Some 2007-2008 vehicles equipped with a remote keyless entry (RKE) transmitter may
exhibit an inoperative Key Fob due to a discharged Key Fob battery. This may be caused by an
internal issue with the Key Fob software. This concern only applies to vehicles built within a specific
date range with Key Fobs manufactured within a specific date range.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
PERFORMING THIS PROCEDURE WILL HAVE NO EFFECT ON KEY FOB RANGE. REFER TO
WORKSHOP MANUAL (WSM), SECTION 501-14 FOR KEY FOB RANGE DIAGNOSTICS.
1. Refer to vehicle list for build date range. (Figure 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Transmitter > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Transmitter:
> 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate > Page 8112
a. If the vehicle was built within the date range, then continue with this procedure.
b. If not, then do not proceed. Continue with normal diagnostics per WSM, Section 501-14.
2. Is the vehicle Key Fob part number 8L3T-15K601-AA (3 button) or 8S4T-15K601-AA (4 button)?
(Figure 2)
a. Yes - Go to Step 3.
b. No - Do not proceed. Continue with normal diagnostics per WSM, Section 501-14.
3. Using a thin coin, open the Key Fob and inspect manufacturer's date code sticker. The first three
digits = day of year. The last digit = year. (Figure 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Transmitter > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Transmitter:
> 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate > Page 8113
a. If the first 3 digits are equal to or between 005 and 306 (5th day through 306th day) and the last
digit is 7 (year), then proceed to Step 4.
b. If the number is outside this specified range, then do not proceed. Continue with normal
diagnostics per WSM, Section 501-14.
4. If the Key Fob is inoperative due to a discharged Key Fob battery, and the date code falls within
the specified range, then replace Key Fob. Program the new Key Fob transmitter using the IDS
RKE Transmitter Programming Procedure. Reassemble old Key Fob for warranty return analysis.
NOTE
KEY FOBS REPLACED UNDER WARRANTY WILL BE REQUESTED FOR ANALYSIS AND
VERIFICATION OF THE DATE CODE.
a. IDS RKE Transmitter Programming Procedure
(1) Install known good battery into the suspect Key Fob so that IDS scan tool can identify it.
(2) Connect IDS to vehicle.
(3) From the Main Toolbox tab:
(a) Select - Body.
(b) Select - Security.
(c) Select - Remote Keyless Entry.
(4) Press the "Unlock" button on the suspect Key Fob to view the Transmitter Identification Code
(TIC) in IDS.
5. Select "Erase One Key Fob" or the "Erase" button.
6. Select the suspect Key Fob TIC to erase from vehicle memory.
7. Remove battery from suspect Key Fob and reassemble for warranty return.
8. Select "Reprogram a New Keyfob" or the "Program" button.
9. Press the "Unlock" button on the NEW Key Fob.
10. Follow the instructions on the scan tool screen to complete the programming procedure.
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
081209A 2008 Focus, Mustang, 0.3 Hr.
Explorer, Explorer Sport Trac, Mountaineer, E-Series, Expedition, Crown Victoria, Grand Marquis,
Ranger, F-Super Duty: Replace Key Fob(s), Includes Time To Perform Key Fob Programming
Procedure, And Verify Date Code Sticker (Do Not Use With 15601A)
081209A 2007-2008 F-150, Mark 0.3 Hr.
LT: Replace Key Fob(s), Includes Time To Perform Key Fob Programming Procedure, And Verify
Date Code Sticker (Do Not Use With 15601A)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Transmitter > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Transmitter:
> 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate > Page 8114
DEALER CODING
CONDITION
BASIC PART NO. CODE
15K601 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry
Transmitter: > 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate
Keyless Entry Transmitter: All Technical Service Bulletins Keyless Entry - Transmitter May Not
Operate
TSB 08-12-9
06/23/08
INOPERATIVE RKE TRANSMITTER (KEY FOB) - DISCHARGED KEY FOB BATTERY
FORD: 2008 Crown Victoria, Focus, Mustang 2007-2008 F-150 2008 E-Series, Expedition,
Explorer Sport Trac, Explorer, F-Super Duty, Ranger
LINCOLN: 2007-2008 Mark LT
MERCURY: 2008 Grand Marquis, Mountaineer
ISSUE Some 2007-2008 vehicles equipped with a remote keyless entry (RKE) transmitter may
exhibit an inoperative Key Fob due to a discharged Key Fob battery. This may be caused by an
internal issue with the Key Fob software. This concern only applies to vehicles built within a specific
date range with Key Fobs manufactured within a specific date range.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
PERFORMING THIS PROCEDURE WILL HAVE NO EFFECT ON KEY FOB RANGE. REFER TO
WORKSHOP MANUAL (WSM), SECTION 501-14 FOR KEY FOB RANGE DIAGNOSTICS.
1. Refer to vehicle list for build date range. (Figure 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry
Transmitter: > 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate > Page 8120
a. If the vehicle was built within the date range, then continue with this procedure.
b. If not, then do not proceed. Continue with normal diagnostics per WSM, Section 501-14.
2. Is the vehicle Key Fob part number 8L3T-15K601-AA (3 button) or 8S4T-15K601-AA (4 button)?
(Figure 2)
a. Yes - Go to Step 3.
b. No - Do not proceed. Continue with normal diagnostics per WSM, Section 501-14.
3. Using a thin coin, open the Key Fob and inspect manufacturer's date code sticker. The first three
digits = day of year. The last digit = year. (Figure 3)
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Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry
Transmitter: > 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate > Page 8121
a. If the first 3 digits are equal to or between 005 and 306 (5th day through 306th day) and the last
digit is 7 (year), then proceed to Step 4.
b. If the number is outside this specified range, then do not proceed. Continue with normal
diagnostics per WSM, Section 501-14.
4. If the Key Fob is inoperative due to a discharged Key Fob battery, and the date code falls within
the specified range, then replace Key Fob. Program the new Key Fob transmitter using the IDS
RKE Transmitter Programming Procedure. Reassemble old Key Fob for warranty return analysis.
NOTE
KEY FOBS REPLACED UNDER WARRANTY WILL BE REQUESTED FOR ANALYSIS AND
VERIFICATION OF THE DATE CODE.
a. IDS RKE Transmitter Programming Procedure
(1) Install known good battery into the suspect Key Fob so that IDS scan tool can identify it.
(2) Connect IDS to vehicle.
(3) From the Main Toolbox tab:
(a) Select - Body.
(b) Select - Security.
(c) Select - Remote Keyless Entry.
(4) Press the "Unlock" button on the suspect Key Fob to view the Transmitter Identification Code
(TIC) in IDS.
5. Select "Erase One Key Fob" or the "Erase" button.
6. Select the suspect Key Fob TIC to erase from vehicle memory.
7. Remove battery from suspect Key Fob and reassemble for warranty return.
8. Select "Reprogram a New Keyfob" or the "Program" button.
9. Press the "Unlock" button on the NEW Key Fob.
10. Follow the instructions on the scan tool screen to complete the programming procedure.
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
081209A 2008 Focus, Mustang, 0.3 Hr.
Explorer, Explorer Sport Trac, Mountaineer, E-Series, Expedition, Crown Victoria, Grand Marquis,
Ranger, F-Super Duty: Replace Key Fob(s), Includes Time To Perform Key Fob Programming
Procedure, And Verify Date Code Sticker (Do Not Use With 15601A)
081209A 2007-2008 F-150, Mark 0.3 Hr.
LT: Replace Key Fob(s), Includes Time To Perform Key Fob Programming Procedure, And Verify
Date Code Sticker (Do Not Use With 15601A)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry
Transmitter: > 08-12-9 > Jun > 08 > Keyless Entry - Transmitter May Not Operate > Page 8122
DEALER CODING
CONDITION
BASIC PART NO. CODE
15K601 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 8125
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.
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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 8126
Keyless Entry Transmitter: Testing and Inspection Stepped Unlock Programming
STEPPED UNLOCK PROGRAMMING
1. With the ignition switch in the OFF position, press the LOCK and UNLOCK buttons on the
remote keyless entry (RKE) transmitter
simultaneously for 4 seconds. The parking lamps will flash twice to indicate the mode change.
2. Repeat STEP 1 to enable/disable the stepped unlocking feature.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Transmitter > Component Information > Service and Repair > Remote Memory Activation
Keyless Entry Transmitter: Service and Repair 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Transmitter > Component Information > Service and Repair > Remote Memory Activation > Page 8129
Keyless Entry Transmitter: Service and Repair 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 (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec
> 10 > SYNC(R) System - Poor Cell Phone Audio Quality
Technical Service Bulletin # 10-25-12 Date: 101223
SYNC(R) System - Poor Cell Phone Audio Quality
TSB 10-25-12
12/23/10
SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE
RECOGNITION DIFFICULTIES WHILE DRIVING
FORD: 2008-2009 Fusion, Taurus X, Taurus 2008-2011 Focus 2008-2010 Edge, Explorer Sport
Trac, Explorer 2009-2010 F-150, F-Super Duty, Flex 2009-2011 Escape, Expedition
LINCOLN: 2008-2009 MKZ 2009-2011 MKS 2008-2010 MKX 2009-2011 Navigator
MERCURY: 2008-2009 Milan, Sable 2008-2010 Mountaineer 2009-2011 Mariner
This article supersedes TSB 10-8-4 to update the vehicle model years, Service Procedure and the
Part List. The new SYNC service Microphone kit now includes a voltage filter incorporated into the
jumper harness.
ISSUE Some customers of 2008-2011 SYNC equipped vehicles may express concern with their
call sound quality while using the SYNC microphone, complaints of excessive background noise
during a phone call and/or issues with voice recognition accuracy while driving.
ACTION Follow the service procedure to correct the condition.
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
MT102512 Claim Diagnosis And Labor Actual
Performed As Actual Time. Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
17700 42
Disclaimer
Service Procedure
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec
> 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 8139
The following procedure involves updating the Accessory Protocol Interface Module (APIM)
software level and installing an external alternate SYNC microphone attached to the headliner.
NOTE
THIS PROCEDURE DOES NOT APPLY TO VEHICLES EQUIPPED WITH HEADLINER
MICROPHONE OR DEALER-INSTALLED SYNC SYSTEMS.
Go to Step 2 if the vehicle is already equipped with SYNC 3.0 Traffic and Directions or has already
been upgraded to latest available consumer interface processor (CIP) level 9L3T-14D544-AE
without E911/VHR, 9L2T-14D544-BE with E911/VHR or later versions. To determine the current
APIM software level, Refer to the Professional Technician Society (PTS) website, enter the VIN in
OASIS, click the GO button and select the SYNC button.
1. Reprogram the APIM to CIP software level 9L3T-1 4D544-AE without E9 11 /VHR,
9L2T-14D544-BE with E911/VHR or later version. For
additional information Refer to other SYNC TSB's and WSM, Section 418-01. Service Pack files
may also be obtained at www.syncmyride.com.
When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to
test VR functionality while the vehicle is parked. If customer concerns are still present, this
procedure will not yield an improvement and the service procedure should not be performed.
Instead, refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to
assist customer.
The VR experience can be improved with user training and making improvements to the phone
book entries (longer entries make the system more robust). Ensure the customer does not try to
speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce
system effectiveness.
When diagnosing a concern related to call sound quality, expect marginal improvements for calls
described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints
where the call audio seems to drop out intermittently.
NOTE
THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO
THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO
NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING
WITH MICROPHONE INSTALLATION.
2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone
directly to the headliner and splicing in a jumper
harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be
functional. The jumper harness is equipped with a voltage filter. The filter will need to be wrapped
in soft foam 164-R4901 or flock tape 164-R4903 from the Rotunda squeak and rattle kit 164-R4900
to prevent interior squeak/rattle noise.
a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone
installation and wire splicing locations. Refer to
Wiring Diagram (WD), Section 5-1 for recommended splicing methods.
b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or
functionality.
c. The microphone is directional. Make sure the microphone is always positioned so wire length is
minimized from view. When installing the
microphone adjacent to trim, place the microphone as close to trim as possible to help minimize
visible wire.
Edge / MKX
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 1)
^ Firmly press the microphone into place.
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Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec
> 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 8140
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information.
3. Route microphone cable up through existing hole in the headliner and over to the driver side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124 for
links to location and connector views.
6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C211. Cut the three circuits on the
female side of the connector (14334 harness).
These are the microphone positive, negative and shield circuits. Then splice the yellow jumper
harness wire to VMM13 and any two of the three black jumper harness wires to RMM13 and
DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off
and secure the cut wire ends heading up the A-pillar as they are no longer used.
7. Identify circuits CBP41 and GD133 from C210. This is power and ground for both the new
microphone and the existing mirror. Splice in the blue
jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure
that the original circuits remain intact and connected as this is power for other items within the rear
view mirror and in the roof.
8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps.
Escape / Mariner
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration (Figures 2 and 3). Firmly
press the microphone into place. Ensure the microphone is parallel and adjacent to overhead
console trim (if equipped) or positioned directly above A-pillar on headliner if not equipped with an
overhead console. Proceed to Step 5 if not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner and over to the driver side
A-pillar. It may be necessary to slightly drop headliner to
run microphone cable.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec
> 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 8141
5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124 for links to
location and connector views.
6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C214. Cut the three circuits on the
female side of the connector (14334 harness).
These are the microphone positive, negative and shield circuits. Then splice the yellow jumper
harness wire to VMM13 and any two of the three black jumper harness wires to RMM13 and
DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off
and secure the cut wire ends heading up the A-pillar as they are no longer used.
7. Identify circuits CBP41 and GD182 from C214. This is power and ground for both the new
microphone and the existing mirror. Splice in the blue
jumper harness wire to CBP41 and the remaining black jumper harness wire to GD1 82. Ensure
that the original circuits remain intact and connected as this is power for other items within the rear
view mirror and in the roof.
8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps.
Navigator / Expedition
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figures 4 and 5)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped) or
positioned directly above A-pillar on headliner if not equipped with an overhead console.
^ Proceed to Step 5 if not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information.
3. Route microphone cable through existing hole in the headliner and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online
WD, Section 124 for links to location and connector
views.
6. Identify circuits VMN07, RMNO7 and DMN07 (shield) from C298. Cut the three circuits on the
female side of the connector (17C712 harness).
These are the microphone positive, negative and shield circuits. Then splice the yellow jumper
harness wire to VMNO7 and any two (of the three) black jumper harness wires to RMNO7 and
DMNO7 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off
and secure the cut wire ends heading up the A-pillar as they are no longer used.
7. Identify circuits CBP41 and GD133 from C298. This is power and ground for both the new
microphone and the existing mirror. Splice in the blue
jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure
that the original circuits remain intact and connected as this is power for other items within the rear
view mirror and in the roof.
8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps.
Explorer / Explorer Sport Trac / Mountaineer
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 6)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec
> 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 8142
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information.
3. Route microphone cable through existing hole in the headliner and over to the driver side
A-pillar. It may be necessary to slightly drop headliner to
run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124 for links to
location and connector views.
6. Identify circuits VMNO7, RMNO7 and DMNO7 (shield) from C248 (Sport Trac uses C260). Cut
the three circuits on the female side of the
connector (14334 harness). These are the microphone positive, negative and shield circuits. Then
splice the yellow jumper harness wire to VMNO7 and any two (of the three) black jumper harness
wires to RMNO7 and DMNO7 (shield). Only splice into the cut wires heading in the direction of the
connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer
used.
7. Identify circuits CBPO5 and GD143 from C248. This is power and ground for both the new
microphone and the existing mirror. Splice in the blue
jumper harness wire to CBPO5 and the remaining black jumper harness wire to GD143. Ensure
that the original circuits remain intact and connected as this is power for other items within the rear
view mirror and in the roof.
8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps.
F-150
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 7)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp.
2. Lower the overhead console or front lamp. Refer to WSM, Section 501-12 for additional
information.
3. Route microphone cable through existing hole in the headliner and temporarily tuck excess wire
into headliner to the rear of the console or lamp.
4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or
front lamp trim directly behind microphone as
shown.
5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD,
Section 124 for links to location and connector views.
6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C314. Cut the three circuits on the
female side of the connector (14358 harness).
These are the microphone positive, negative and shield circuits. Then splice the yellow jumper
harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and
DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off
and secure the cut wire ends heading up the A-pillar as they are no longer used.
7. Identify circuits CBP41 from C315 and GD133 from C314. This is power and ground for both the
new microphone and the existing mirror. Splice in
the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133.
Ensure that the original circuits remain intact and connected as this is power for other items within
the rear view mirror and in the roof.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec
> 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 8143
8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps.
F-Super Duty
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 8)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
c. This repair is not recommended for vehicles not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information.
3. Route microphone cable through existing hole in the headliner and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124 for links to
location and connector views.
6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C264. Cut the three circuits on the
female side of the connector (17K745 harness).
These are the microphone positive, negative and shield circuits. Then splice the yellow jumper
harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and
DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off
and secure the cut wire ends heading up the A-pillar as they are no longer used
7. Identify circuits CBP41 and GD133 from C264. This is power and ground for both the new
microphone and the existing mirror. Splice in the blue
jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure
that the original circuits remain intact and connected as this is power for other items within the rear
view mirror and in the roof.
8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps.
Flex
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Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec
> 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 8144
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 9)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information.
3. Route microphone cable through existing hole in the headliner and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124 for links to
location and connector views.
6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C925. Cut the three circuits on the
female side of the connector (14334 harness).
These are the microphone positive, negative and shield circuits. Then splice the yellow jumper
harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and
DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off
and secure the cut wire ends heading up the A-pillar as they are no longer used.
7. Identify circuits CBP41 and GD133 from C925. This is power and ground for both the new
microphone and the existing mirror. Splice in the blue
jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure
that the original circuits remain intact and connected as this is power for other items within the rear
view mirror and in the roof.
8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps.
Focus
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 10) Firmly press
the microphone into place. Ensure the microphone is parallel and adjacent to the interior lamp trim.
2. Lower the interior lamp assembly. Refer to WSM, Section 417-02 for additional information.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec
> 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 8145
3. Route microphone cable up through existing hole in the headliner and over to the passenger
side A-pillar. It may be necessary to slightly drop
headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install interior lamp assembly; ensure microphone cable enters the interior lamp trim directly
behind microphone as shown.
5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector
views.
6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C934. Cut the three circuits on the
female side of the connector (14334 harness).
These are the microphone positive, negative and shield circuits. Then splice the yellow jumper
harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and
DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off
and secure the cut wire ends heading up the A-pillar as they are no longer used.
7. Identify circuits CPL6O and GD161 from C934. This is power and ground for both the new
microphone and the existing mirror. Splice in the blue
jumper harness wire to CPL6O and the remaining black jumper harness wire to GD161. Ensure
that the original circuits remain intact and connected as this is power for other items within the rear
view mirror and in the roof.
8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps.
Fusion / Milan / MKZ
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 11)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information.
3. Route microphone cable through existing hole in the headliner and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124 for links to
location and connector views.
6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C913. Cut the three circuits on the
female side of the connector (14334 harness).
These are the microphone positive, negative and shield circuits. Then splice the yellow jumper
harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and
DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off
and secure the cut wire ends heading up the A-pillar as they are no longer used.
7. Identify circuits CBPO2 and GD139 from C913. This is power and ground for both the new
microphone and the existing mirror. Splice in the blue
jumper harness wire to CBPO2 and the remaining black jumper harness wire to GD139. Ensure
that the original circuits remain intact and connected as this is power for other items within the rear
view mirror and in the roof.
8. Do not plug in the microphone at this time proceed to Final Test / Service Steps.
Taurus / Sable / Taurus X
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec
> 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 8146
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 12)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information.
3. Route microphone cable through existing hole in the headliner and over to the driver side
A-pillar. It may be necessary to slightly drop headliner to
run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124 for links to
location and connector views.
6. Identify circuits VMN02, RMN02 and DMN07 (shield) from C925. Cut the three circuits on the
female side of the connector (17K745 harness).
These are the microphone positive, negative and shield circuits. Then splice the yellow jumper
harness wire to VMN02 and any two (of the three) black jumper harness wires to RMN02 and
DMNO7 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off
and secure the cut wire ends heading up the A-pillar as they are no longer used.
7. Identify circuits CBP41 and GD133 from C925. This is power and ground for both the new
microphone and the existing mirror. Splice in the blue
jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure
that the original circuits remain intact and connected as this is power for other items within the rear
view mirror and in the roof.
8. Do not plug in the microphone at this time, proceed to Final Test I Service Steps.
MKS
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 13)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec
> 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 8147
2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information.
3. Route microphone cable through existing hole in the headliner and out the front of the headliner
above the rear view mirror.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124 for
links to location and connector views.
6. Identify circuits VMN02, RMNO2 and DMN07 (shield) from C911. Pull back the black harness
sleeve and cut the three circuits near C911 or if
equipped with a headlamp control module-2 (HCM-2), remove the HCM-2 access cover and cut
circuits under trim cover. Refer to WSM Section 417-01 for additional information. These are the
microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to
VMNO2 and remaining black jumper harness wires to RMNO2 and DMNO7 (shield). Only splice
into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends
heading up the A-pillar as they are no longer used.
7. Identify circuits CBP41 and GD133 from C911. This is power and ground for both the new
microphone and the existing mirror. Splice in the blue
jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure
that the original circuits remain intact and connected as this is power for other items within the rear
view mirror and in the roof.
8. Do not plug in the microphone at this time, proceed to Final Test I Service Steps.
Final Test / Service Steps
1. After splicing/soldering is complete, apply power to the vehicle and confirm the voltage at the
jumper inline connector before connecting the
microphone.
^ Jumper blue wire equal 12V positive.
^ Jumper black wire equal ground reference.
^ Jumper yellow wire equal microphone return signal circuit less than IV.
2. Turn off ignition and attach the microphone connector to the jumper harness connector. Make
sure that the connector tabs have locked together after
connecting. Reversing this connector would cause a failure of the microphone.
3. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul >
09 > SYNC(R) System - Poor Cell Phone Sound Quality
Cellular Phone Microphone: Customer Interest SYNC(R) System - Poor Cell Phone Sound Quality
TSB 09-13-5
07/13/09
SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE
RECOGNITION DIFFICULTIES WHILE DRIVING
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009
Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner
ISSUE Some customers of 2008-2009 SYNC equipped vehicles may express concern with their
call sound quality while using the SYNC microphone, complaints of excessive background noise
during a phone call, and/or issues with voice recognition accuracy while driving.
ACTION Follow the service procedure to correct the condition.
SERVICE PROCEDURE
The following service procedure involves updating the Accessory Protocol Interface Module (APIM)
software level and installing an external alternate SYNC microphone attached to the headliner.
NOTE
THIS PROCEDURE DOES NOT APPLY TO DEALER-INSTALLED SYNC SYSTEMS.
Do not perform Step 1 if vehicle is already equipped with SYNC 2.0 (911 and Vehicle Health
Report) or has been upgraded to consumer interface processor (CIP) level 9L3T-14D544-AE. To
determine the current APIM software level, Refer to the Professional Technician Society (PTS)
website, enter the VIN in OASIS, click the GO button, and select the SYNC button.
1. Reprogram the APIM to CIP software level 9L3T-14D544-AE. For additional information Refer to
other SYNC TSB's and WSM, Section 418-01.
Service Pack files may also be obtained at www.syncmyride.com.
When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to
test VR functionality while the vehicle is parked. If customer concerns are still present, this
procedure will not yield an improvement, and the service procedure should not be performed.
Instead, Refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to
assist customer.
The VR experience can be improved with user training and making improvements to the phone
book entries (longer entries make the system more robust). Ensure the customer does not try to
speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce
system effectiveness.
When diagnosing a concern related to call sound quality, expect marginal improvements for calls
described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints
where the call audio seems to drop out intermittently.
NOTE
THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO
THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO
NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING
WITH MICROPHONE INSTALLATION.
2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone
directly to the headliner and splicing in a jumper
harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be
functional.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul >
09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8152
a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone
installation and wire splicing locations. Refer to
Wiring Diagram (WD), Section 5-1 for recommended splicing methods.
b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or
functionality.
c. The microphone is directional. Make sure the microphone is always positioned so wire length is
minimized from view. When installing the
microphone adjacent to trim, place microphone as close to trim as possible to help minimize visible
wire.
2008-2009 Edge / MKX
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 1)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable up through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124-1 for
links to location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C211. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C210.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
cut wire ends heading up the A-pillar as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2009 Escape / Mariner
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul >
09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8153
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration (Figures 2 and 3). Firmly
press the microphone into place. Ensure the microphone is parallel and adjacent to overhead
console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an
overhead console. Proceed to Step 5 if not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 501-05 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner to
run microphone cable.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C214. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP41 (BU) and GD182 (BK-GY) from C214.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD1 82 (BK-GY).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
cut wire ends heading up the A-pillar as they are no longer used.
9. Connect the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2008-2009 Navigator / 2009 Expedition
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul >
09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8154
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figures 4 and 5)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or
positioned directly above A-pillar on headliner if not
equipped with an overhead console.
^ Proceed to Step 5 if not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online
WD, Section 124-1 for links to location and connector
views.
6. Identify circuits VMN07 (GY), RMN07 (VT), and DMN07 (shield - BK) from C298. Cut the three
circuits on the male side of the connector
(17C712 harness).
7. Identify circuits CBP31 (BU-OG) and GD133 (BK) from C298 (2008 Navigator only). Identify
circuits CBP41 (BU) and GD133 (BK) from C298
(2009 Expedition/Navigator only).
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP31 (BU-OG) and any black jumper harness wire to GD133 (BK)
for 2008 Navigator only. Blue jumper harness wire to CBP41 (BU) and any black jumper harness
wire to GD133 (BK) for 2009 Expedition/Navigator only.
^ Ensure original circuits remain connected in splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul >
09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8155
^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07
(VT) and DMN07 (shield - BK).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Connect the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the headliner.
2008-2009 Explorer / Explorer Sport Trac / Mountaineer
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 6)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner run
microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify and cut circuits VMNO7 (GY), RMNO7 (VT), and DMNO7 (shield) from C248. Cut the
three circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP05 (YE) and GD143 (BK-VT) from C248.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP05 (YE) and any black jumper harness wire to GD143 (BK-VT).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07
(VT) and DMN07 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
cut wire ends heading up the A-pillar as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2009 F-150
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul >
09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8156
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 7)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp.
2. Lower the overhead console or front lamp. Refer to WSM, Section 417-02 for additional
information.
3. Route microphone cable through existing hole in the headliner, and temporarily tuck excess wire
into headliner to the rear of the console or lamp.
4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or
front lamp trim directly behind microphone as
shown.
5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD,
Section 124-1 for links to location and connector
views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C314. Cut the three
circuits on the female side of the connector
(14358 harness).
7. Identify circuits CBP41 (BU) from C315 and GD133 (BK) from C314.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the headliner.
2009 F-Super Duty
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul >
09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8157
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 8)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
c. This repair is not recommended for vehicles not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield - BK) from C264. Cut the
three circuits on the female side of the connector
(17K745 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C264.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield - BK).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Connect the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2009 Flex
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul >
09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8158
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 9)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C925. Cut the three
circuits on the female side of the connector (14334 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C925.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2008-2009 Focus
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul >
09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8159
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration (Figure 10). Firmly press
the microphone into place. Ensure the microphone is parallel and adjacent to the dome lamp trim.
2. Lower the dome lamp assembly. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable up through existing hole in the headliner, and over to the passenger
side A-pillar. It may be necessary to slightly drop
headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install dome lamp assembly; ensure microphone cable enters the dome lamp trim directly behind
microphone as shown.
5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector
views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C934. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CPL60 (BN-YE) and GD161 (BK-YE) from C934.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CPL60 (BN-YE) and any black jumper harness wire to GD161
(BK-YE).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2008-2009 Fusion / Milan / MKZ
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul >
09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8160
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 11)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C913. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP02 (GN) and GD139 (BK-YE) from C913.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP02 (GN) and any black jumper harness wire to GD139 (BK-YE).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2008-2009 Taurus / Sable / Taurus X
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 12)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner to
run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul >
09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8161
5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMN02 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C925. Cut the
three circuits on the female side of the connector
(17K745 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C925.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to
RMN02 (VT-BN) and DMN07 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2009 MKS
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 13)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and out the front of the headliner
above the rear view mirror.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124-1 for
links to location and connector views.
6. Identify circuits VMNO2 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C911. Pull back
the black harness sleeve and cut the three
circuits near C91 1 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2
access cover and cut circuits under trim cover. Refer to WSM, Section 417-01 for additional
information.
7. Identify circuits CBP41 (BU) and GD133 (BK) from C911.
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Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul >
09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8162
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to
RMN02 (VT-BN) and DMN07 (shield).
^ Only splice into the wires heading away from the connector. The wires heading into the connector
(mirror) are no longer used.
^ Ensure the wiring is neatly routed from the splice locations into the headliner, following the
existing wire harness routing from mirror to headliner.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
OTHER APPLICABLE ARTICLES: 08-21-2
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
MT091305 Claim Diagnosis And Labor Actual
Performed As Actual Time. Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
17700 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: >
10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality
Technical Service Bulletin # 10-25-12 Date: 101223
SYNC(R) System - Poor Cell Phone Audio Quality
TSB 10-25-12
12/23/10
SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE
RECOGNITION DIFFICULTIES WHILE DRIVING
FORD: 2008-2009 Fusion, Taurus X, Taurus 2008-2011 Focus 2008-2010 Edge, Explorer Sport
Trac, Explorer 2009-2010 F-150, F-Super Duty, Flex 2009-2011 Escape, Expedition
LINCOLN: 2008-2009 MKZ 2009-2011 MKS 2008-2010 MKX 2009-2011 Navigator
MERCURY: 2008-2009 Milan, Sable 2008-2010 Mountaineer 2009-2011 Mariner
This article supersedes TSB 10-8-4 to update the vehicle model years, Service Procedure and the
Part List. The new SYNC service Microphone kit now includes a voltage filter incorporated into the
jumper harness.
ISSUE Some customers of 2008-2011 SYNC equipped vehicles may express concern with their
call sound quality while using the SYNC microphone, complaints of excessive background noise
during a phone call and/or issues with voice recognition accuracy while driving.
ACTION Follow the service procedure to correct the condition.
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
MT102512 Claim Diagnosis And Labor Actual
Performed As Actual Time. Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
17700 42
Disclaimer
Service Procedure
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: >
10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 8168
The following procedure involves updating the Accessory Protocol Interface Module (APIM)
software level and installing an external alternate SYNC microphone attached to the headliner.
NOTE
THIS PROCEDURE DOES NOT APPLY TO VEHICLES EQUIPPED WITH HEADLINER
MICROPHONE OR DEALER-INSTALLED SYNC SYSTEMS.
Go to Step 2 if the vehicle is already equipped with SYNC 3.0 Traffic and Directions or has already
been upgraded to latest available consumer interface processor (CIP) level 9L3T-14D544-AE
without E911/VHR, 9L2T-14D544-BE with E911/VHR or later versions. To determine the current
APIM software level, Refer to the Professional Technician Society (PTS) website, enter the VIN in
OASIS, click the GO button and select the SYNC button.
1. Reprogram the APIM to CIP software level 9L3T-1 4D544-AE without E9 11 /VHR,
9L2T-14D544-BE with E911/VHR or later version. For
additional information Refer to other SYNC TSB's and WSM, Section 418-01. Service Pack files
may also be obtained at www.syncmyride.com.
When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to
test VR functionality while the vehicle is parked. If customer concerns are still present, this
procedure will not yield an improvement and the service procedure should not be performed.
Instead, refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to
assist customer.
The VR experience can be improved with user training and making improvements to the phone
book entries (longer entries make the system more robust). Ensure the customer does not try to
speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce
system effectiveness.
When diagnosing a concern related to call sound quality, expect marginal improvements for calls
described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints
where the call audio seems to drop out intermittently.
NOTE
THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO
THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO
NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING
WITH MICROPHONE INSTALLATION.
2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone
directly to the headliner and splicing in a jumper
harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be
functional. The jumper harness is equipped with a voltage filter. The filter will need to be wrapped
in soft foam 164-R4901 or flock tape 164-R4903 from the Rotunda squeak and rattle kit 164-R4900
to prevent interior squeak/rattle noise.
a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone
installation and wire splicing locations. Refer to
Wiring Diagram (WD), Section 5-1 for recommended splicing methods.
b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or
functionality.
c. The microphone is directional. Make sure the microphone is always positioned so wire length is
minimized from view. When installing the
microphone adjacent to trim, place the microphone as close to trim as possible to help minimize
visible wire.
Edge / MKX
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 1)
^ Firmly press the microphone into place.
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^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information.
3. Route microphone cable up through existing hole in the headliner and over to the driver side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124 for
links to location and connector views.
6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C211. Cut the three circuits on the
female side of the connector (14334 harness).
These are the microphone positive, negative and shield circuits. Then splice the yellow jumper
harness wire to VMM13 and any two of the three black jumper harness wires to RMM13 and
DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off
and secure the cut wire ends heading up the A-pillar as they are no longer used.
7. Identify circuits CBP41 and GD133 from C210. This is power and ground for both the new
microphone and the existing mirror. Splice in the blue
jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure
that the original circuits remain intact and connected as this is power for other items within the rear
view mirror and in the roof.
8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps.
Escape / Mariner
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration (Figures 2 and 3). Firmly
press the microphone into place. Ensure the microphone is parallel and adjacent to overhead
console trim (if equipped) or positioned directly above A-pillar on headliner if not equipped with an
overhead console. Proceed to Step 5 if not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner and over to the driver side
A-pillar. It may be necessary to slightly drop headliner to
run microphone cable.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: >
10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 8170
5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124 for links to
location and connector views.
6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C214. Cut the three circuits on the
female side of the connector (14334 harness).
These are the microphone positive, negative and shield circuits. Then splice the yellow jumper
harness wire to VMM13 and any two of the three black jumper harness wires to RMM13 and
DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off
and secure the cut wire ends heading up the A-pillar as they are no longer used.
7. Identify circuits CBP41 and GD182 from C214. This is power and ground for both the new
microphone and the existing mirror. Splice in the blue
jumper harness wire to CBP41 and the remaining black jumper harness wire to GD1 82. Ensure
that the original circuits remain intact and connected as this is power for other items within the rear
view mirror and in the roof.
8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps.
Navigator / Expedition
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figures 4 and 5)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped) or
positioned directly above A-pillar on headliner if not equipped with an overhead console.
^ Proceed to Step 5 if not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information.
3. Route microphone cable through existing hole in the headliner and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online
WD, Section 124 for links to location and connector
views.
6. Identify circuits VMN07, RMNO7 and DMN07 (shield) from C298. Cut the three circuits on the
female side of the connector (17C712 harness).
These are the microphone positive, negative and shield circuits. Then splice the yellow jumper
harness wire to VMNO7 and any two (of the three) black jumper harness wires to RMNO7 and
DMNO7 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off
and secure the cut wire ends heading up the A-pillar as they are no longer used.
7. Identify circuits CBP41 and GD133 from C298. This is power and ground for both the new
microphone and the existing mirror. Splice in the blue
jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure
that the original circuits remain intact and connected as this is power for other items within the rear
view mirror and in the roof.
8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps.
Explorer / Explorer Sport Trac / Mountaineer
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 6)
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^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information.
3. Route microphone cable through existing hole in the headliner and over to the driver side
A-pillar. It may be necessary to slightly drop headliner to
run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124 for links to
location and connector views.
6. Identify circuits VMNO7, RMNO7 and DMNO7 (shield) from C248 (Sport Trac uses C260). Cut
the three circuits on the female side of the
connector (14334 harness). These are the microphone positive, negative and shield circuits. Then
splice the yellow jumper harness wire to VMNO7 and any two (of the three) black jumper harness
wires to RMNO7 and DMNO7 (shield). Only splice into the cut wires heading in the direction of the
connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer
used.
7. Identify circuits CBPO5 and GD143 from C248. This is power and ground for both the new
microphone and the existing mirror. Splice in the blue
jumper harness wire to CBPO5 and the remaining black jumper harness wire to GD143. Ensure
that the original circuits remain intact and connected as this is power for other items within the rear
view mirror and in the roof.
8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps.
F-150
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 7)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp.
2. Lower the overhead console or front lamp. Refer to WSM, Section 501-12 for additional
information.
3. Route microphone cable through existing hole in the headliner and temporarily tuck excess wire
into headliner to the rear of the console or lamp.
4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or
front lamp trim directly behind microphone as
shown.
5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD,
Section 124 for links to location and connector views.
6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C314. Cut the three circuits on the
female side of the connector (14358 harness).
These are the microphone positive, negative and shield circuits. Then splice the yellow jumper
harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and
DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off
and secure the cut wire ends heading up the A-pillar as they are no longer used.
7. Identify circuits CBP41 from C315 and GD133 from C314. This is power and ground for both the
new microphone and the existing mirror. Splice in
the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133.
Ensure that the original circuits remain intact and connected as this is power for other items within
the rear view mirror and in the roof.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: >
10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 8172
8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps.
F-Super Duty
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 8)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
c. This repair is not recommended for vehicles not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information.
3. Route microphone cable through existing hole in the headliner and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124 for links to
location and connector views.
6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C264. Cut the three circuits on the
female side of the connector (17K745 harness).
These are the microphone positive, negative and shield circuits. Then splice the yellow jumper
harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and
DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off
and secure the cut wire ends heading up the A-pillar as they are no longer used
7. Identify circuits CBP41 and GD133 from C264. This is power and ground for both the new
microphone and the existing mirror. Splice in the blue
jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure
that the original circuits remain intact and connected as this is power for other items within the rear
view mirror and in the roof.
8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps.
Flex
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Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: >
10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 8173
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 9)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information.
3. Route microphone cable through existing hole in the headliner and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124 for links to
location and connector views.
6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C925. Cut the three circuits on the
female side of the connector (14334 harness).
These are the microphone positive, negative and shield circuits. Then splice the yellow jumper
harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and
DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off
and secure the cut wire ends heading up the A-pillar as they are no longer used.
7. Identify circuits CBP41 and GD133 from C925. This is power and ground for both the new
microphone and the existing mirror. Splice in the blue
jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure
that the original circuits remain intact and connected as this is power for other items within the rear
view mirror and in the roof.
8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps.
Focus
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 10) Firmly press
the microphone into place. Ensure the microphone is parallel and adjacent to the interior lamp trim.
2. Lower the interior lamp assembly. Refer to WSM, Section 417-02 for additional information.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: >
10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 8174
3. Route microphone cable up through existing hole in the headliner and over to the passenger
side A-pillar. It may be necessary to slightly drop
headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install interior lamp assembly; ensure microphone cable enters the interior lamp trim directly
behind microphone as shown.
5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector
views.
6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C934. Cut the three circuits on the
female side of the connector (14334 harness).
These are the microphone positive, negative and shield circuits. Then splice the yellow jumper
harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and
DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off
and secure the cut wire ends heading up the A-pillar as they are no longer used.
7. Identify circuits CPL6O and GD161 from C934. This is power and ground for both the new
microphone and the existing mirror. Splice in the blue
jumper harness wire to CPL6O and the remaining black jumper harness wire to GD161. Ensure
that the original circuits remain intact and connected as this is power for other items within the rear
view mirror and in the roof.
8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps.
Fusion / Milan / MKZ
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 11)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information.
3. Route microphone cable through existing hole in the headliner and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124 for links to
location and connector views.
6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C913. Cut the three circuits on the
female side of the connector (14334 harness).
These are the microphone positive, negative and shield circuits. Then splice the yellow jumper
harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and
DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off
and secure the cut wire ends heading up the A-pillar as they are no longer used.
7. Identify circuits CBPO2 and GD139 from C913. This is power and ground for both the new
microphone and the existing mirror. Splice in the blue
jumper harness wire to CBPO2 and the remaining black jumper harness wire to GD139. Ensure
that the original circuits remain intact and connected as this is power for other items within the rear
view mirror and in the roof.
8. Do not plug in the microphone at this time proceed to Final Test / Service Steps.
Taurus / Sable / Taurus X
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: >
10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 8175
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 12)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information.
3. Route microphone cable through existing hole in the headliner and over to the driver side
A-pillar. It may be necessary to slightly drop headliner to
run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124 for links to
location and connector views.
6. Identify circuits VMN02, RMN02 and DMN07 (shield) from C925. Cut the three circuits on the
female side of the connector (17K745 harness).
These are the microphone positive, negative and shield circuits. Then splice the yellow jumper
harness wire to VMN02 and any two (of the three) black jumper harness wires to RMN02 and
DMNO7 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off
and secure the cut wire ends heading up the A-pillar as they are no longer used.
7. Identify circuits CBP41 and GD133 from C925. This is power and ground for both the new
microphone and the existing mirror. Splice in the blue
jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure
that the original circuits remain intact and connected as this is power for other items within the rear
view mirror and in the roof.
8. Do not plug in the microphone at this time, proceed to Final Test I Service Steps.
MKS
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 13)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: >
10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 8176
2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information.
3. Route microphone cable through existing hole in the headliner and out the front of the headliner
above the rear view mirror.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124 for
links to location and connector views.
6. Identify circuits VMN02, RMNO2 and DMN07 (shield) from C911. Pull back the black harness
sleeve and cut the three circuits near C911 or if
equipped with a headlamp control module-2 (HCM-2), remove the HCM-2 access cover and cut
circuits under trim cover. Refer to WSM Section 417-01 for additional information. These are the
microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to
VMNO2 and remaining black jumper harness wires to RMNO2 and DMNO7 (shield). Only splice
into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends
heading up the A-pillar as they are no longer used.
7. Identify circuits CBP41 and GD133 from C911. This is power and ground for both the new
microphone and the existing mirror. Splice in the blue
jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure
that the original circuits remain intact and connected as this is power for other items within the rear
view mirror and in the roof.
8. Do not plug in the microphone at this time, proceed to Final Test I Service Steps.
Final Test / Service Steps
1. After splicing/soldering is complete, apply power to the vehicle and confirm the voltage at the
jumper inline connector before connecting the
microphone.
^ Jumper blue wire equal 12V positive.
^ Jumper black wire equal ground reference.
^ Jumper yellow wire equal microphone return signal circuit less than IV.
2. Turn off ignition and attach the microphone connector to the jumper harness connector. Make
sure that the connector tabs have locked together after
connecting. Reversing this connector would cause a failure of the microphone.
3. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: >
09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality
Cellular Phone Microphone: All Technical Service Bulletins SYNC(R) System - Poor Cell Phone
Sound Quality
TSB 09-13-5
07/13/09
SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE
RECOGNITION DIFFICULTIES WHILE DRIVING
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009
Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner
ISSUE Some customers of 2008-2009 SYNC equipped vehicles may express concern with their
call sound quality while using the SYNC microphone, complaints of excessive background noise
during a phone call, and/or issues with voice recognition accuracy while driving.
ACTION Follow the service procedure to correct the condition.
SERVICE PROCEDURE
The following service procedure involves updating the Accessory Protocol Interface Module (APIM)
software level and installing an external alternate SYNC microphone attached to the headliner.
NOTE
THIS PROCEDURE DOES NOT APPLY TO DEALER-INSTALLED SYNC SYSTEMS.
Do not perform Step 1 if vehicle is already equipped with SYNC 2.0 (911 and Vehicle Health
Report) or has been upgraded to consumer interface processor (CIP) level 9L3T-14D544-AE. To
determine the current APIM software level, Refer to the Professional Technician Society (PTS)
website, enter the VIN in OASIS, click the GO button, and select the SYNC button.
1. Reprogram the APIM to CIP software level 9L3T-14D544-AE. For additional information Refer to
other SYNC TSB's and WSM, Section 418-01.
Service Pack files may also be obtained at www.syncmyride.com.
When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to
test VR functionality while the vehicle is parked. If customer concerns are still present, this
procedure will not yield an improvement, and the service procedure should not be performed.
Instead, Refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to
assist customer.
The VR experience can be improved with user training and making improvements to the phone
book entries (longer entries make the system more robust). Ensure the customer does not try to
speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce
system effectiveness.
When diagnosing a concern related to call sound quality, expect marginal improvements for calls
described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints
where the call audio seems to drop out intermittently.
NOTE
THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO
THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO
NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING
WITH MICROPHONE INSTALLATION.
2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone
directly to the headliner and splicing in a jumper
harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be
functional.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: >
09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8181
a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone
installation and wire splicing locations. Refer to
Wiring Diagram (WD), Section 5-1 for recommended splicing methods.
b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or
functionality.
c. The microphone is directional. Make sure the microphone is always positioned so wire length is
minimized from view. When installing the
microphone adjacent to trim, place microphone as close to trim as possible to help minimize visible
wire.
2008-2009 Edge / MKX
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 1)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable up through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124-1 for
links to location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C211. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C210.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
cut wire ends heading up the A-pillar as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2009 Escape / Mariner
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: >
09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8182
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration (Figures 2 and 3). Firmly
press the microphone into place. Ensure the microphone is parallel and adjacent to overhead
console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an
overhead console. Proceed to Step 5 if not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 501-05 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner to
run microphone cable.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C214. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP41 (BU) and GD182 (BK-GY) from C214.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD1 82 (BK-GY).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
cut wire ends heading up the A-pillar as they are no longer used.
9. Connect the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2008-2009 Navigator / 2009 Expedition
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: >
09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8183
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figures 4 and 5)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or
positioned directly above A-pillar on headliner if not
equipped with an overhead console.
^ Proceed to Step 5 if not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online
WD, Section 124-1 for links to location and connector
views.
6. Identify circuits VMN07 (GY), RMN07 (VT), and DMN07 (shield - BK) from C298. Cut the three
circuits on the male side of the connector
(17C712 harness).
7. Identify circuits CBP31 (BU-OG) and GD133 (BK) from C298 (2008 Navigator only). Identify
circuits CBP41 (BU) and GD133 (BK) from C298
(2009 Expedition/Navigator only).
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP31 (BU-OG) and any black jumper harness wire to GD133 (BK)
for 2008 Navigator only. Blue jumper harness wire to CBP41 (BU) and any black jumper harness
wire to GD133 (BK) for 2009 Expedition/Navigator only.
^ Ensure original circuits remain connected in splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: >
09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8184
^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07
(VT) and DMN07 (shield - BK).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Connect the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the headliner.
2008-2009 Explorer / Explorer Sport Trac / Mountaineer
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 6)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner run
microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify and cut circuits VMNO7 (GY), RMNO7 (VT), and DMNO7 (shield) from C248. Cut the
three circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP05 (YE) and GD143 (BK-VT) from C248.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP05 (YE) and any black jumper harness wire to GD143 (BK-VT).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07
(VT) and DMN07 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
cut wire ends heading up the A-pillar as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2009 F-150
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: >
09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8185
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 7)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp.
2. Lower the overhead console or front lamp. Refer to WSM, Section 417-02 for additional
information.
3. Route microphone cable through existing hole in the headliner, and temporarily tuck excess wire
into headliner to the rear of the console or lamp.
4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or
front lamp trim directly behind microphone as
shown.
5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD,
Section 124-1 for links to location and connector
views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C314. Cut the three
circuits on the female side of the connector
(14358 harness).
7. Identify circuits CBP41 (BU) from C315 and GD133 (BK) from C314.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the headliner.
2009 F-Super Duty
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: >
09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8186
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 8)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
c. This repair is not recommended for vehicles not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield - BK) from C264. Cut the
three circuits on the female side of the connector
(17K745 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C264.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield - BK).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Connect the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2009 Flex
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: >
09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8187
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 9)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C925. Cut the three
circuits on the female side of the connector (14334 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C925.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2008-2009 Focus
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: >
09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8188
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration (Figure 10). Firmly press
the microphone into place. Ensure the microphone is parallel and adjacent to the dome lamp trim.
2. Lower the dome lamp assembly. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable up through existing hole in the headliner, and over to the passenger
side A-pillar. It may be necessary to slightly drop
headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install dome lamp assembly; ensure microphone cable enters the dome lamp trim directly behind
microphone as shown.
5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector
views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C934. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CPL60 (BN-YE) and GD161 (BK-YE) from C934.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CPL60 (BN-YE) and any black jumper harness wire to GD161
(BK-YE).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2008-2009 Fusion / Milan / MKZ
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: >
09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8189
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 11)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C913. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP02 (GN) and GD139 (BK-YE) from C913.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP02 (GN) and any black jumper harness wire to GD139 (BK-YE).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2008-2009 Taurus / Sable / Taurus X
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 12)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner to
run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: >
09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8190
5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMN02 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C925. Cut the
three circuits on the female side of the connector
(17K745 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C925.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to
RMN02 (VT-BN) and DMN07 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2009 MKS
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 13)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and out the front of the headliner
above the rear view mirror.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124-1 for
links to location and connector views.
6. Identify circuits VMNO2 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C911. Pull back
the black harness sleeve and cut the three
circuits near C91 1 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2
access cover and cut circuits under trim cover. Refer to WSM, Section 417-01 for additional
information.
7. Identify circuits CBP41 (BU) and GD133 (BK) from C911.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: >
09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8191
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to
RMN02 (VT-BN) and DMN07 (shield).
^ Only splice into the wires heading away from the connector. The wires heading into the connector
(mirror) are no longer used.
^ Ensure the wiring is neatly routed from the splice locations into the headliner, following the
existing wire harness routing from mirror to headliner.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
OTHER APPLICABLE ARTICLES: 08-21-2
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
MT091305 Claim Diagnosis And Labor Actual
Performed As Actual Time. Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
17700 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > Customer Interest: > 10-2-8 > Feb > 10 > SYNC(R) System Defaults To 'Privacy Mode'
Communications Control Module: Customer Interest SYNC(R) System - Defaults To 'Privacy Mode'
TSB 10-2-8
02/15/10
SYNC SYSTEM DEFAULTS TO OR STAYS IN PRIVACY MODE, MULTIPLE VEHICLE LINES
FORD: 2008-2009 Taurus X 2008-2010 Focus, Fusion, Mustang, Taurus, Edge, Escape,
Expedition, Explorer Sport Trac, Explorer, F-150, F-250, F-350, F-450 2009-2010 Flex
LINCOLN: 2008-2010 MKZ 2009-2010 MKS 2008 Mark LT 2008-2010 MKX, Navigator 2010 MKT
MERCURY: 2008-2009 Sable 2008-2010 Milan, Mariner, Mountaineer
ISSUE Some customers of 2008-2010 SYNC-equipped vehicles may express concern with their
SYNC paired device defaulting, switching or staying on privacy mode. The customer may not be
able to accept the call through the SYNC system or must answer the call manually on their
personal device.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Set the Privacy mode to Off on the device and recheck Sync operation.
2. If necessary, test the device on another vehicle with the same version SYNC. If the concern is
still present, the device is the concern. Continue with
normal WSM Diagnostics.
NOTE
PRIVACY MODE MEANS THAT THE PHONE IS CONTROLLING THE AUDIO. SYNC ONLY
MAKES REQUESTS TO THE PHONE TO TRANSFER THIS RESPONSIBILITY OR AUDIO TO
SYNC. IF THE PHONE DOES NOT ACCEPT THIS REQUEST OR THERE IS A PROBLEM IN
THE COMMUNICATION TO MAKE THIS HAPPEN, YOU ARE BY DEFAULT IN PRIVACY MODE.
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > Customer Interest: > 09-26-8 > Jan > 10 > SYNC(R) System Software Update For Various Concerns
Communications Control Module: Customer Interest SYNC(R) System - Software Update For
Various Concerns
TSB 09-26-8
01/04/10
SYNC SOFTWARE UPDATE - VARIOUS ISSUES
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009
Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner
This article supersedes TSB 9-22-14 to update the Service Procedure.
ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following
symptoms:
^ Universal Serial Bus (USB) port inoperative.
^ USB audio muting when using various non-Apple USB devices.
^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands.
^ Excessive background noise and/or poor voice sound quality.
^ Phone book auto download inoperative on supported devices.
^ SYNC steering wheel control (SWC) switches being inoperative intermittently.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace
processor (CIP) software levels.
^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report)
^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health
Report)
Service Pack files may be obtained at www.syncmyride.com.
Reprogram the APIM
Contains software fix updates for the following:
^ Phone book auto download inoperative.
^ USB audio muting.
^ SYNC steering wheel control (SWC) switches being inoperative.
^ Voice recognition on 2-digit entries.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > Customer Interest: > 09-26-8 > Jan > 10 > SYNC(R) System Software Update For Various Concerns > Page 8204
^ USB port inoperative with diagnostic trouble code (DTC) B1342.
^ Poor call sound quality.
This software update also contains enhancements that will improve the reliability of both Bluetooth
and USB connections to SYNC(R) from various consumer devices, and microphone enhancements
to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The
Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple
call handling and other mobile phone features. The USB enhancements improve support for media
players and the playing of file formats and podcasts.
NOTE
REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC
SOFTWARE PROGRAMMING TIPS.
1. Connect the vehicle communication module (VCM) to the data link connector (DLC).
2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software.
3. Turn the ignition key to the on position.
4. Launch IDS tool.
5. If required, update the VCM with the latest software.
6. Close the IDS tool.
7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle
communication is established, press the GO button.
8. From the Vehicle Service Session screen, Select the SYNC button.
9. Press read APIM button.
10. Select software and press program APIM to update the SYNC module.
NOTE
YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER
CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP.
NOTE
DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING.
NOTE
THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW
THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY
INCLUDED IN WINDOWS XP.
11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP).
NOTE
DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE.
a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the
IDS tool or laptop running IDS software and
to the vehicle USB port.
b. Follow the on-screen instructions to program both processors on the Sync module (VIP and
CIP).
12. At the end of the configuration and programming procedure, the programming has been
completed successfully screen will be displayed.
13. Exit PTS, disconnect the VCM and disconnect the USB cable.
OTHER APPLICABLE ARTICLES: 08-21-02
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
092608A 2008-2009 Edge, Explorer, 0.4 Hr.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > Customer Interest: > 09-26-8 > Jan > 10 > SYNC(R) System Software Update For Various Concerns > Page 8205
Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus,
Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty,
Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14D212 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System Functions Inoperative/DTC's Set
Communications Control Module: Customer Interest SYNC(R) System - Functions
Inoperative/DTC's Set
TSB 09-14-3
07/27/09
SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY
DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED
FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge,
Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid,
Mariner
ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist
and Vehicle Health Report, may exhibit all or most of the following symptoms:
^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface
Module (APIM)
^ SYNC display menus/options blank
^ USB port inoperative
^ No SYNC Blue Tooth device connectivity
^ Voice/Phone/OK steering wheel controls inoperative
^ Lack of APIM communication
^ Parasitic battery draw with APIM connected
These symptoms may be triggered by a low battery state of charge, or a recent battery
disconnect/reconnect.
ACTION Follow the service procedure to correct the condition.
SERVICE PROCEDURE
This software upgrade only applies to the following Accessory Protocol Interface Module (APIM)
Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels:
^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC
^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD
^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD
To determine the current APIM software level, reference the Professional Technician Society (PTS)
website, enter the VIN in OASIS, click the GO
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System Functions Inoperative/DTC's Set > Page 8210
button and select the SYNC button.
1. Determine if communication can be established with the APIM using IDS.
a. If communication cannot be verified, proceed to Step 2.
b. If communication is present, proceed to Step 3.
2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if
communication can be established. If not, perform
an APIM power reset by disconnecting and reconnecting the vehicle battery.
a. If communication is now present, proceed to Step 3.
b. If communication still cannot be established, replace the APIM.
3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure.
NOTE
SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE
THROUGH THE SYNCMYRIDE.COM WEBSITE.
NOTE
CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS
APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID
AND PASSWORD.
a. Connect the vehicle communication module (VCM) to the data link connector (DLC).
b. Connect the VCM to the IDS tool or laptop running IDS software.
c. Turn the ignition key to the on position.
d. Launch IDS tool.
e. If required, update the VCM with the latest software.
f. Close the IDS tool.
g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle
communication is established, press the GO
button.
h. From the Vehicle Service Session screen, Select the SYNC button.
i. Press read APIM button.
j. Select software and press program APIM to update the SYNC module.
NOTE
YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER
CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP.
NOTE
DO NOT USE A TRANSFER TYPE CABLE.
NOTE
DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING.
NOTE
THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW
THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY
INCLUDED IN WINDOWS XP.
k. Program the processor in the APIM.
l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the
IDS tool or laptop running IDS software, and to the vehicle USB port.
m. Follow the on-screen instructions to program the VIP module.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System Functions Inoperative/DTC's Set > Page 8211
n. At the end of the configuration and programming procedure, the programming has been
completed successfully screen will be displayed.
o. Exit PTS, disconnect the VCM and disconnect the USB cable.
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
MT091403 Use SLTS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor Performed As Actual Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14D212 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-2-8 > Feb > 10 > SYNC(R)
System - Defaults To 'Privacy Mode'
Communications Control Module: All Technical Service Bulletins SYNC(R) System - Defaults To
'Privacy Mode'
TSB 10-2-8
02/15/10
SYNC SYSTEM DEFAULTS TO OR STAYS IN PRIVACY MODE, MULTIPLE VEHICLE LINES
FORD: 2008-2009 Taurus X 2008-2010 Focus, Fusion, Mustang, Taurus, Edge, Escape,
Expedition, Explorer Sport Trac, Explorer, F-150, F-250, F-350, F-450 2009-2010 Flex
LINCOLN: 2008-2010 MKZ 2009-2010 MKS 2008 Mark LT 2008-2010 MKX, Navigator 2010 MKT
MERCURY: 2008-2009 Sable 2008-2010 Milan, Mariner, Mountaineer
ISSUE Some customers of 2008-2010 SYNC-equipped vehicles may express concern with their
SYNC paired device defaulting, switching or staying on privacy mode. The customer may not be
able to accept the call through the SYNC system or must answer the call manually on their
personal device.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Set the Privacy mode to Off on the device and recheck Sync operation.
2. If necessary, test the device on another vehicle with the same version SYNC. If the concern is
still present, the device is the concern. Continue with
normal WSM Diagnostics.
NOTE
PRIVACY MODE MEANS THAT THE PHONE IS CONTROLLING THE AUDIO. SYNC ONLY
MAKES REQUESTS TO THE PHONE TO TRANSFER THIS RESPONSIBILITY OR AUDIO TO
SYNC. IF THE PHONE DOES NOT ACCEPT THIS REQUEST OR THERE IS A PROBLEM IN
THE COMMUNICATION TO MAKE THIS HAPPEN, YOU ARE BY DEFAULT IN PRIVACY MODE.
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-26-8 > Jan > 10 > SYNC(R)
System - Software Update For Various Concerns
Communications Control Module: All Technical Service Bulletins SYNC(R) System - Software
Update For Various Concerns
TSB 09-26-8
01/04/10
SYNC SOFTWARE UPDATE - VARIOUS ISSUES
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009
Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner
This article supersedes TSB 9-22-14 to update the Service Procedure.
ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following
symptoms:
^ Universal Serial Bus (USB) port inoperative.
^ USB audio muting when using various non-Apple USB devices.
^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands.
^ Excessive background noise and/or poor voice sound quality.
^ Phone book auto download inoperative on supported devices.
^ SYNC steering wheel control (SWC) switches being inoperative intermittently.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace
processor (CIP) software levels.
^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report)
^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health
Report)
Service Pack files may be obtained at www.syncmyride.com.
Reprogram the APIM
Contains software fix updates for the following:
^ Phone book auto download inoperative.
^ USB audio muting.
^ SYNC steering wheel control (SWC) switches being inoperative.
^ Voice recognition on 2-digit entries.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-26-8 > Jan > 10 > SYNC(R)
System - Software Update For Various Concerns > Page 8221
^ USB port inoperative with diagnostic trouble code (DTC) B1342.
^ Poor call sound quality.
This software update also contains enhancements that will improve the reliability of both Bluetooth
and USB connections to SYNC(R) from various consumer devices, and microphone enhancements
to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The
Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple
call handling and other mobile phone features. The USB enhancements improve support for media
players and the playing of file formats and podcasts.
NOTE
REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC
SOFTWARE PROGRAMMING TIPS.
1. Connect the vehicle communication module (VCM) to the data link connector (DLC).
2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software.
3. Turn the ignition key to the on position.
4. Launch IDS tool.
5. If required, update the VCM with the latest software.
6. Close the IDS tool.
7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle
communication is established, press the GO button.
8. From the Vehicle Service Session screen, Select the SYNC button.
9. Press read APIM button.
10. Select software and press program APIM to update the SYNC module.
NOTE
YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER
CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP.
NOTE
DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING.
NOTE
THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW
THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY
INCLUDED IN WINDOWS XP.
11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP).
NOTE
DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE.
a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the
IDS tool or laptop running IDS software and
to the vehicle USB port.
b. Follow the on-screen instructions to program both processors on the Sync module (VIP and
CIP).
12. At the end of the configuration and programming procedure, the programming has been
completed successfully screen will be displayed.
13. Exit PTS, disconnect the VCM and disconnect the USB cable.
OTHER APPLICABLE ARTICLES: 08-21-02
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
092608A 2008-2009 Edge, Explorer, 0.4 Hr.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-26-8 > Jan > 10 > SYNC(R)
System - Software Update For Various Concerns > Page 8222
Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus,
Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty,
Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14D212 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-14-3 > Jul > 09 > SYNC(R)
System - Functions Inoperative/DTC's Set
Communications Control Module: All Technical Service Bulletins SYNC(R) System - Functions
Inoperative/DTC's Set
TSB 09-14-3
07/27/09
SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY
DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED
FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge,
Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid,
Mariner
ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist
and Vehicle Health Report, may exhibit all or most of the following symptoms:
^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface
Module (APIM)
^ SYNC display menus/options blank
^ USB port inoperative
^ No SYNC Blue Tooth device connectivity
^ Voice/Phone/OK steering wheel controls inoperative
^ Lack of APIM communication
^ Parasitic battery draw with APIM connected
These symptoms may be triggered by a low battery state of charge, or a recent battery
disconnect/reconnect.
ACTION Follow the service procedure to correct the condition.
SERVICE PROCEDURE
This software upgrade only applies to the following Accessory Protocol Interface Module (APIM)
Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels:
^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC
^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD
^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD
To determine the current APIM software level, reference the Professional Technician Society (PTS)
website, enter the VIN in OASIS, click the GO
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-14-3 > Jul > 09 > SYNC(R)
System - Functions Inoperative/DTC's Set > Page 8227
button and select the SYNC button.
1. Determine if communication can be established with the APIM using IDS.
a. If communication cannot be verified, proceed to Step 2.
b. If communication is present, proceed to Step 3.
2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if
communication can be established. If not, perform
an APIM power reset by disconnecting and reconnecting the vehicle battery.
a. If communication is now present, proceed to Step 3.
b. If communication still cannot be established, replace the APIM.
3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure.
NOTE
SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE
THROUGH THE SYNCMYRIDE.COM WEBSITE.
NOTE
CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS
APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID
AND PASSWORD.
a. Connect the vehicle communication module (VCM) to the data link connector (DLC).
b. Connect the VCM to the IDS tool or laptop running IDS software.
c. Turn the ignition key to the on position.
d. Launch IDS tool.
e. If required, update the VCM with the latest software.
f. Close the IDS tool.
g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle
communication is established, press the GO
button.
h. From the Vehicle Service Session screen, Select the SYNC button.
i. Press read APIM button.
j. Select software and press program APIM to update the SYNC module.
NOTE
YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER
CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP.
NOTE
DO NOT USE A TRANSFER TYPE CABLE.
NOTE
DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING.
NOTE
THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW
THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY
INCLUDED IN WINDOWS XP.
k. Program the processor in the APIM.
l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the
IDS tool or laptop running IDS software, and to the vehicle USB port.
m. Follow the on-screen instructions to program the VIP module.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-14-3 > Jul > 09 > SYNC(R)
System - Functions Inoperative/DTC's Set > Page 8228
n. At the end of the configuration and programming procedure, the programming has been
completed successfully screen will be displayed.
o. Exit PTS, disconnect the VCM and disconnect the USB cable.
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
MT091403 Use SLTS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor Performed As Actual Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14D212 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications 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 (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: >
09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 8234
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: >
09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 8240
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Locations > Audio Control Module
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Locations > Audio Control Module > Page 8243
View 151-17
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Diagrams > Accessory Protocol Interface Module (APIM)
Communications Control Module: Diagrams Accessory Protocol Interface Module (APIM)
C3342 (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 8246
C3342 (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 8247
Communications Control Module: Diagrams Audio Control Module
C290A
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Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 8248
C290B
C290C
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Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Diagrams > Page 8249
Communications Control Module: Service and Repair
AUDIO CONTROL MODULE (ACM)
Removal and Installation
NOTE:
- When installing a new navigation audio control module (ACM), remove the navigation DVD before
sending the ACM to an authorized audio system repair facility.
- It is not necessary to remove the ACM to retrieve the part number.
1. NOTE: Module configuration is only required if a new ACM is being installed.
Upload the ACM configuration information to the scan tool. Refer to Information Bus (Module
Configuration) to carry out programmable module installation (PMI). See: Powertrain
Management/Computers and Control Systems/Information Bus/Testing and
Inspection/Programming and Relearning
2. Remove the instrument panel center finish panel. 3. Remove the 4 screws and the ACM.
- Disconnect the ACM electrical connectors and the antenna lead-in cable(s).
4. To install, reverse the removal procedure.
- Download the configuration information to the ACM.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 151-24
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Parking Assist Control Module > Component Information > Locations > Page 8254
View 151-25
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Parking Assist Control Module > Component Information > Locations > Page 8255
View 151-26
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Control Module > Component Information > Locations > Page 8256
Parking Assist Control Module: Diagrams
C3267
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Parking Assist Control Module > Component Information > Locations > Page 8257
C4014
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Parking Assist Control Module > Component Information > Locations > Page 8258
C4226
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Parking Assist Control Module > Component Information > Locations > Page 8259
Parking Assist Control Module: Service and Repair
PARKING AID MODULE
Removal and Installation
1. Disconnect the parking aid module (PAM) 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 PAM bumper harness from the PAM. 5. Remove the 2 PAM
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 (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Locations
Parking Assist Distance Sensor: Locations
View 151-26
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Parking Assist Distance Sensor > Component Information > Locations > Page 8263
View 151-27
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
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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 8266
C4011
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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 8267
C4010
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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 8268
C4012
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Warning Indicator > Component Information > Diagrams
Parking Assist Warning Indicator: Diagrams
C3268
C4015
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Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Locations
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Information > Locations > Page 8275
C253
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Information > Locations > Page 8276
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 SELECT/RESET button on base instrument
clusters (IC), and by the message center switches on high series instrument clusters (IC). 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 (V8-4.6L (2008))
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. 2. Visually inspect for obvious signs of mechanical or electrical
damage.
Visual Inspection Chart
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
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 (IC).
9. If the DTCs retrieved are related to the concern, go to DTC Charts. For all other DTCs, refer to
Body Control Systems (Multifunction Electronic
Control Module). See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Trouble Code Descriptions/Information and Message Center
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
NOTE: The smart junction box (SJB) is also known as the generic electronic module (GEM).
The message center information can be selected through the SELECT/RESET button (base
cluster) and by the INFO, SETUP, and RESET buttons (high series cluster).
The message center is an integral part of the instrument cluster (IC) that receives and acts upon
much of the same information that is input and used to operate the instrument cluster (IC) gauges,
informational indicators, and warning indicators. The message center, located in the center of the
instrument cluster (IC) is a liquid crystal display (LCD). The message center electronic functions
use both hardwired and the controller area network (CAN) circuitry to transmit and receive
information.
Whenever conditions are present that require a warning message, the message center replaces
the last selected display with the new warning display. Once the message is reset or cleared, the
message center returns to the last selected display. If multiple warnings are present, the message
center displays each warning for approximately 4 seconds. Warning messages are also generally
associated with other observable instrument cluster (IC) indications.
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8279
For example, when the LH front door is opened, the message center displays the message
DRIVER DOOR AJAR along with the door ajar warning indicator. This allows the message center
to be a more informative supplement to the instrument cluster (IC) gauges and indicators.
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 that received the input (message) controls the output of the feature, or if it outputs a
message over the CAN to another module.
- which module controls the output of the feature.
Instrument Cluster (IC) Network Messages
NOTE: Whenever a network message is suspected as missing, confirmed by a missing message
DTC, it is important to look for other symptoms that may also be present in the instrument cluster
(IC) and throughout the vehicle. Once a DTC is set in the instrument cluster (IC), it may be helpful
to review the complete message list available in Information Bus (Module Communications
Network) to see what other modules also rely on the same message and run the self-test for those
modules. If the message is missing from other modules, the same DTC may also be set in those
modules. Confirmation of missing messages common to multiple modules may indicate that the
originating module is the source of the concern or the communication network may be experiencing
some problems.
The instrument cluster (IC) uses input messages from other modules to control the gauges,
informational indicators, warning indicators and message center displays over the communication
networks. If a required message is missing or invalid for less than 5 seconds, the gauge or
indicator that requires the message remains at the last commanded state based upon the last
known good message. For example, if the message is missing for the driver door ajar off status for
less than 5 seconds and the door ajar indicator was on, the indicator remains in the on state until
the next good message is received. If the message remains missing or invalid for greater than 5
seconds, the instrument cluster (IC) sets a U-code DTC and the output becomes a default action
for the indicator or gauge. Each indicator or gauge utilizes a different default strategy depending on
the nature of the indication. Refer to Instrument Cluster for further descriptions of the default action
specific to each indicator or gauge. If the messaged input to the cluster returns at any time, the
normal function of the gauge or indicator resumes.
Message Center Features
The message center provides the following features: Information displays
- Setup displays
- System check messages
- Warning messages
Information Displays (Base Instrument Cluster [IC])
The information displays are non-timed modes. The selected mode remains on until the driver
presses the SELECT/RESET 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 (if equipped)
- Distance to empty
- Average fuel economy
- Setup menu
Information Displays (High Series Instrument Cluster [IC])
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
- Distance to empty
- Average fuel economy
- Instantaneous fuel economy
- Fuel used
- Trip elapsed drive time
- Blank
Setup Displays (Base Instrument Cluster [IC])
The setup displays are timed modes and terminate after a finite interval. Press the
SELECT/RESET button to scroll through the SETUP MENU display sequence. If the
SELECT/RESET button is not pressed within 4 seconds, the message center returns to the INFO
MENU. The setup display modes are: System check
- Units (English/metric)
- Language
- Autolamp
- Autolock
- Auto-unlock
- Parking aid (if equipped)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8280
- Oil life reset and start value
Setup Displays (High Series Instrument Cluster [IC])
The setup displays are timed modes and terminate after a finite interval. Press the SETUP button
for the following displays: System check
- Units (English/metric)
- Language
- Autolamp
- Autolock
- Auto-unlock
- Running boards (if equipped)
- Easy entry/exit seat (if equipped)
- Parking aid (if equipped)
- Compass zone
- Compass calibration
- Oil life reset and 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 (IC), the
SELECT/RESET button must be held down after pressing the SELECT/RESET button to cycle the
messages through each of the systems being monitored. For high series instrument clusters (IC),
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
- CHARGING SYSTEM
- WASHER FLUID
- DOOR AJAR
- EXTERIOR LAMPS
- BRAKE FLUID LEVEL
- PARK BRAKE
- FUEL LEVEL AND DISTANCE TO EMPTY (high series instrument cluster [IC])
- MILES TO EMPTY (base instrument cluster [IC])
- FUEL LEVEL LOW (base instrument cluster [IC])
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
The warning messages that reoccur after 10 minutes are: 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 (if equipped)
- 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
- CLEAR OBJECTS BY PASS SEAT
- CHECK CHARGING SYSTEM
- LOW TIRE PRESSURE
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8281
- TIRE MONITOR FAULT
- TIRE SENSOR FAULT
The message center displays messages that indicate a system state during the operation of the
four wheel drive (4WD) system. The displayed warning messages are as follows: FOR 4X4 LOW STOP VEHICLE (if equipped)
- FOR 4X4 LOW SHIFT TO N (if equipped)
- TO EXIT 4X4 LOW STOP VEHICLE (if equipped)
- TO EXIT 4X4 LOW SHIFT TO N (if equipped)
The message center displays messages that indicate a system state during repair procedures
related to the tire pressure monitoring system (TPMS). The displayed warning messages are as
follows: TRAIN TIRES
- TIRES TRAINED
- TIRES NOT TRAINED
The message center displays messages that indicate a system state during repair procedures
related to the compass display. The displayed warning messages are as follows: COMPASS ZONE XX (base instrument cluster [IC])
- RESET FOR ZONE SETTING (high series instrument cluster [IC])
- ZONE XX RESET TO CHANGE (high series instrument cluster [IC])
- ZONE XX IS SET
- PRESS RESET FOR CALIBRATION (high series instrument cluster [IC])
- CIRCLE SLOW TO CALIBRATE (base instrument cluster [IC])
- CIRCLE SLOWLY TO CALIBRATE (high series instrument cluster [IC])
- CALIBRATION COMPLETED
The message center displays messages that indicate a system state during repair procedures
related to the oil life and oil life start value. The displayed warning messages are as follows: HOLD RESET IF NEW OIL
- OIL LIFE SET TO 100%
- OIL LIFE START VALUE SET TO XXX% (high series instrument cluster [IC])
- OIL LIFE SET TO XXX% (base instrument cluster [IC])
Outside Air Temperature Sensor (Instrument Cluster [IC] Without Electronic Automatic
Temperature Control [EATC])
The instrument cluster (IC) 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 EATC, the outside air temperature data from the
outside air temperature sensor is displayed in the heating ventilation air conditioning (HVAC)
module. Refer to Heating and Air Conditioning for the outside air temperature display in the EATC.
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 (V8-4.6L (2008))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8282
Driver/Vehicle Information Display: Symptom Related Diagnostic Procedures
Symptom Chart (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8283
Symptom Chart (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8284
Symptom Chart (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8285
Symptom Chart (Part 4)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8286
Symptom Chart (Part 5)
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8287
Symptom Chart (Part 6)
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8288
Driver/Vehicle Information Display: Pinpoint Tests
Test A: The Message Center Is Not Operating Correctly (High Series Instrument Cluster [IC])
PINPOINT TEST A: THE MESSAGE CENTER IS NOT OPERATING CORRECTLY (HIGH
SERIES INSTRUMENT CLUSTER [IC])
Normal Operation
The message center functionality is controlled through the message center switch, which is
hardwired to the instrument cluster (IC) through circuits CMC29 (GN/VT) and RMC32 (GN/BU).
This pinpoint test is intended to diagnose the following:
- Message center switch concern
- Instrument cluster (IC)
A1
A2
Test B: The Compass Is Inoperative
PINPOINT TEST B: THE COMPASS IS INOPERATIVE
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 (IC), 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 (IC).
- DTC B2097 (Compass Module Failure) - is a continuous memory DTC that sets in the instrument
cluster (IC) if the data received from the compass module is invalid.
- DTC U2013 (Compass Module is Not Responding) - is a continuous and on-demand DTC that
sets if the instrument cluster (IC) fails to receive a response from the compass module after 4
consecutive attempts.
This pinpoint test is intended to diagnose the following:
- Fuse
- Wiring, terminals or connectors
- Compass sensor module
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8289
B1
B1-B3
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8290
B3-B4
Test C: The Compass Is Inaccurate
PINPOINT TEST C: THE COMPASS IS INACCURATE
Normal Operation
The compass sensor module communicates the vehicle direction to the instrument cluster (IC)
through the compass communication data plus circuit VMC31 (YE/GN) and compass
communication data minus circuit VMC30 (BU/GY). The magnetic fields generated by the earths
north and south poles are divided into zones that differ from each other with respect to how the
magnetic fields appear. The magnetic north can change by up to 4 degrees between zones and
become noticeable across multiple zones. The compass zone must be set to the correct zone for
the compass to read accurately. Factors within the vehicle may affect the ability of the compass
module to accurately read the magnetic north. Calibrating the compass allows the compass module
to compensate for vehicle factors that influence the accuracy of the compass.
This pinpoint test is intended to diagnose the following:
- Calibration
- Zone setting
- Vehicle magnetization
- Compass sensor module
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
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C1-C2
Test D: The Message Center Switch Does Not Operate Correctly (High Series Instrument Cluster
[IC])
PINPOINT TEST D: THE MESSAGE CENTER SWITCH DOES NOT OPERATE CORRECTLY
(HIGH SERIES INSTRUMENT CLUSTER [IC])
Normal Operation
The message center switch uses circuit CMC29 (GN/VT) to communicate the requested switch
function to the instrument cluster (IC) 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 (IC) to determine which switch is pressed.
This pinpoint test is intended to diagnose the following:
- Wiring, terminals or connectors
- Message center switch
- Instrument cluster (IC)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8292
D1-D3
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8293
D3-D5
Test E: The Outside Air Temperature Display Does Not Operate Correctly
PINPOINT TEST E: THE OUTSIDE AIR TEMPERATURE DISPLAY DOES NOT OPERATE
CORRECTLY
NOTE: The outside air temperature display is only available in base instrument clusters (IC) without
electronic automatic temperature control (EATC).
Normal Operation
The outside air temperature sensor is mounted on the radiator core support in front of the radiator
and A/C condenser and is hardwired to the instrument cluster (IC) through input circuit VH407
(YE/GN) and return circuit RMC32 (GN/BU). The instrument cluster (IC) provides a reference
voltage to the ambient air temperature sensor and monitors the change in voltage resulting from
changes in resistance as determined by outside air temperature. When the engine has been off for
an extended period of time, or the engine temperature is cold, the instrument cluster (IC) displays
the
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8294
current outside air temperature as measured by the ambient air temperature sensor. When the
engine has only been turned off for a short time, or if the engine is not cold, the instrument cluster
(IC) takes a reading of the current temperature and compares the current reading against the last
reading at key off. If the temperature is less than the last key off temperature reading, the
instrument cluster (IC) displays the current temperature. If the temperature is greater than the last
key off temperature reading, the instrument cluster (IC) displays the last key off temperature
reading until the ambient air temperature has had time to stabilize with vehicle movement.
- DTC B1255 (Air Temperature External Sensor Circuit Open) - is a continuous and on-demand
DTC that sets if the instrument cluster (IC) detects an open on the outside air temperature sensor
input circuit VH407 (YE/GN). If the instrument cluster (IC) detects an open on the outside air
temperature input, the instrument cluster (IC) defaults the display to 23.5°Celsius (75°F).
- DTC B1257 (Air Temperature External Sensor Circuit Short to Ground) - is a continuous and
on-demand DTC that sets if the instrument cluster (IC) detects a short to ground on the outside air
temperature sensor input circuit VH407 (YE/GN). If the instrument cluster (IC) detects a short to
ground on the outside air temperature input, the instrument cluster (IC) defaults the display to
23.5°Celsius (75°F).
This pinpoint test is intended to diagnose the following:
- Wiring, terminals or connectors
- Ambient air temperature sensor
- Instrument cluster (IC)
E1-E3
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8295
E3-E5
Test F: The WASHER FLUID LOW LEVEL Warning Is Inoperative
PINPOINT TEST F: THE WASHER FLUID LOW LEVEL WARNING IS INOPERATIVE
Normal Operation
The instrument cluster (IC) 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 (IC) through circuit
GD108 (BK/VT) and displaying 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 (IC), and the WASHER FLUID LOW LEVEL warning turns off.
This pinpoint test is intended to diagnose the following:
- Wiring, terminals or connectors
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8296
- Washer fluid level switch (part of the windshield washer reservoir)
- Instrument cluster (IC)
F1-F2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8297
F3-F6
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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F6-F7
Test G: The CHECK CHARGING SYSTEM Warning Is Inoperative
PINPOINT TEST G: THE CHECK CHARGING SYSTEM WARNING IS INOPERATIVE
Normal Operation
The charging system warning indicator is controlled by the instrument cluster (IC) based upon data
received from the PCM over the high speed controller area network (HS-CAN).
This pinpoint test is intended to diagnose the following:
- Charging system
- Instrument cluster (IC)
G1-G2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Service and Repair > Message Center Configuration
Driver/Vehicle Information Display: Service and Repair Message Center Configuration
MESSAGE CENTER CONFIGURATION
Oil Life Reset And Start Value - High Series Instrument Cluster
NOTE: The oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180
days.
1. From the setup menu, press and release the RESET button to display HOLD RESET IF NEW
OIL. 2. Press and hold the RESET button for 2 seconds and release to reset the oil life to 100%. 3.
The message center displays OIL LIFE SET TO 100%. 4. Once the message center displays OIL
LIFE SET TO 100%, release the RESET button then press and release the RESET button to
reduce the start
value (10% for each button press).
Oil Life Reset And Start Value - Base Instrument Cluster
NOTE: Oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days.
- All message center functions are carried out using the single stem reset button in the instrument
cluster.
1. Press and release the SELECT/RESET button to scroll through the information displays until the
message center displays HOLD RESET IF NEW
OIL.
2. Press and hold the SELECT/RESET button for approximately 2 seconds until the message
center displays OIL LIFE SET TO 100%. 3. Once OIL LIFE SET TO 100% is displayed, press and
hold the SELECT/RESET button for more than 2 seconds until the message center displays
OIL LIFE SET TO XXX%.
4. Press and release the SELECT/RESET button to reduce the start value (10% for each button
press). 5. Press and release the SELECT/RESET button to exit the procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Service and Repair > Message Center Configuration > Page 8301
Driver/Vehicle Information Display: Service and Repair Message Center Switch
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 (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Service and Repair > Page 8302
Special Tool(s)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information >
Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set
Emergency Contact Module: Customer Interest SYNC(R) System - Functions Inoperative/DTC's
Set
TSB 09-14-3
07/27/09
SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY
DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED
FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge,
Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid,
Mariner
ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist
and Vehicle Health Report, may exhibit all or most of the following symptoms:
^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface
Module (APIM)
^ SYNC display menus/options blank
^ USB port inoperative
^ No SYNC Blue Tooth device connectivity
^ Voice/Phone/OK steering wheel controls inoperative
^ Lack of APIM communication
^ Parasitic battery draw with APIM connected
These symptoms may be triggered by a low battery state of charge, or a recent battery
disconnect/reconnect.
ACTION Follow the service procedure to correct the condition.
SERVICE PROCEDURE
This software upgrade only applies to the following Accessory Protocol Interface Module (APIM)
Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels:
^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC
^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD
^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD
To determine the current APIM software level, reference the Professional Technician Society (PTS)
website, enter the VIN in OASIS, click the GO
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set
> Page 8311
button and select the SYNC button.
1. Determine if communication can be established with the APIM using IDS.
a. If communication cannot be verified, proceed to Step 2.
b. If communication is present, proceed to Step 3.
2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if
communication can be established. If not, perform
an APIM power reset by disconnecting and reconnecting the vehicle battery.
a. If communication is now present, proceed to Step 3.
b. If communication still cannot be established, replace the APIM.
3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure.
NOTE
SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE
THROUGH THE SYNCMYRIDE.COM WEBSITE.
NOTE
CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS
APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID
AND PASSWORD.
a. Connect the vehicle communication module (VCM) to the data link connector (DLC).
b. Connect the VCM to the IDS tool or laptop running IDS software.
c. Turn the ignition key to the on position.
d. Launch IDS tool.
e. If required, update the VCM with the latest software.
f. Close the IDS tool.
g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle
communication is established, press the GO
button.
h. From the Vehicle Service Session screen, Select the SYNC button.
i. Press read APIM button.
j. Select software and press program APIM to update the SYNC module.
NOTE
YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER
CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP.
NOTE
DO NOT USE A TRANSFER TYPE CABLE.
NOTE
DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING.
NOTE
THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW
THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY
INCLUDED IN WINDOWS XP.
k. Program the processor in the APIM.
l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the
IDS tool or laptop running IDS software, and to the vehicle USB port.
m. Follow the on-screen instructions to program the VIP module.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set
> Page 8312
n. At the end of the configuration and programming procedure, the programming has been
completed successfully screen will be displayed.
o. Exit PTS, disconnect the VCM and disconnect the USB cable.
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
MT091403 Use SLTS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor Performed As Actual Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14D212 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information >
Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality
Emergency Contact Module: Customer Interest SYNC(R) System - Poor Cell Phone Sound Quality
TSB 09-13-5
07/13/09
SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE
RECOGNITION DIFFICULTIES WHILE DRIVING
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009
Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner
ISSUE Some customers of 2008-2009 SYNC equipped vehicles may express concern with their
call sound quality while using the SYNC microphone, complaints of excessive background noise
during a phone call, and/or issues with voice recognition accuracy while driving.
ACTION Follow the service procedure to correct the condition.
SERVICE PROCEDURE
The following service procedure involves updating the Accessory Protocol Interface Module (APIM)
software level and installing an external alternate SYNC microphone attached to the headliner.
NOTE
THIS PROCEDURE DOES NOT APPLY TO DEALER-INSTALLED SYNC SYSTEMS.
Do not perform Step 1 if vehicle is already equipped with SYNC 2.0 (911 and Vehicle Health
Report) or has been upgraded to consumer interface processor (CIP) level 9L3T-14D544-AE. To
determine the current APIM software level, Refer to the Professional Technician Society (PTS)
website, enter the VIN in OASIS, click the GO button, and select the SYNC button.
1. Reprogram the APIM to CIP software level 9L3T-14D544-AE. For additional information Refer to
other SYNC TSB's and WSM, Section 418-01.
Service Pack files may also be obtained at www.syncmyride.com.
When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to
test VR functionality while the vehicle is parked. If customer concerns are still present, this
procedure will not yield an improvement, and the service procedure should not be performed.
Instead, Refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to
assist customer.
The VR experience can be improved with user training and making improvements to the phone
book entries (longer entries make the system more robust). Ensure the customer does not try to
speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce
system effectiveness.
When diagnosing a concern related to call sound quality, expect marginal improvements for calls
described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints
where the call audio seems to drop out intermittently.
NOTE
THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO
THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO
NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING
WITH MICROPHONE INSTALLATION.
2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone
directly to the headliner and splicing in a jumper
harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be
functional.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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> Page 8317
a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone
installation and wire splicing locations. Refer to
Wiring Diagram (WD), Section 5-1 for recommended splicing methods.
b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or
functionality.
c. The microphone is directional. Make sure the microphone is always positioned so wire length is
minimized from view. When installing the
microphone adjacent to trim, place microphone as close to trim as possible to help minimize visible
wire.
2008-2009 Edge / MKX
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 1)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable up through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124-1 for
links to location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C211. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C210.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
cut wire ends heading up the A-pillar as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2009 Escape / Mariner
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information >
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> Page 8318
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration (Figures 2 and 3). Firmly
press the microphone into place. Ensure the microphone is parallel and adjacent to overhead
console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an
overhead console. Proceed to Step 5 if not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 501-05 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner to
run microphone cable.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C214. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP41 (BU) and GD182 (BK-GY) from C214.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD1 82 (BK-GY).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
cut wire ends heading up the A-pillar as they are no longer used.
9. Connect the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2008-2009 Navigator / 2009 Expedition
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information >
Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality
> Page 8319
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figures 4 and 5)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or
positioned directly above A-pillar on headliner if not
equipped with an overhead console.
^ Proceed to Step 5 if not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online
WD, Section 124-1 for links to location and connector
views.
6. Identify circuits VMN07 (GY), RMN07 (VT), and DMN07 (shield - BK) from C298. Cut the three
circuits on the male side of the connector
(17C712 harness).
7. Identify circuits CBP31 (BU-OG) and GD133 (BK) from C298 (2008 Navigator only). Identify
circuits CBP41 (BU) and GD133 (BK) from C298
(2009 Expedition/Navigator only).
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP31 (BU-OG) and any black jumper harness wire to GD133 (BK)
for 2008 Navigator only. Blue jumper harness wire to CBP41 (BU) and any black jumper harness
wire to GD133 (BK) for 2009 Expedition/Navigator only.
^ Ensure original circuits remain connected in splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information >
Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality
> Page 8320
^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07
(VT) and DMN07 (shield - BK).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Connect the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the headliner.
2008-2009 Explorer / Explorer Sport Trac / Mountaineer
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 6)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner run
microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify and cut circuits VMNO7 (GY), RMNO7 (VT), and DMNO7 (shield) from C248. Cut the
three circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP05 (YE) and GD143 (BK-VT) from C248.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP05 (YE) and any black jumper harness wire to GD143 (BK-VT).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07
(VT) and DMN07 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
cut wire ends heading up the A-pillar as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2009 F-150
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information >
Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality
> Page 8321
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 7)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp.
2. Lower the overhead console or front lamp. Refer to WSM, Section 417-02 for additional
information.
3. Route microphone cable through existing hole in the headliner, and temporarily tuck excess wire
into headliner to the rear of the console or lamp.
4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or
front lamp trim directly behind microphone as
shown.
5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD,
Section 124-1 for links to location and connector
views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C314. Cut the three
circuits on the female side of the connector
(14358 harness).
7. Identify circuits CBP41 (BU) from C315 and GD133 (BK) from C314.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the headliner.
2009 F-Super Duty
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information >
Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality
> Page 8322
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 8)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
c. This repair is not recommended for vehicles not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield - BK) from C264. Cut the
three circuits on the female side of the connector
(17K745 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C264.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield - BK).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Connect the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2009 Flex
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information >
Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality
> Page 8323
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 9)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C925. Cut the three
circuits on the female side of the connector (14334 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C925.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2008-2009 Focus
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information >
Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality
> Page 8324
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration (Figure 10). Firmly press
the microphone into place. Ensure the microphone is parallel and adjacent to the dome lamp trim.
2. Lower the dome lamp assembly. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable up through existing hole in the headliner, and over to the passenger
side A-pillar. It may be necessary to slightly drop
headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install dome lamp assembly; ensure microphone cable enters the dome lamp trim directly behind
microphone as shown.
5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector
views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C934. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CPL60 (BN-YE) and GD161 (BK-YE) from C934.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CPL60 (BN-YE) and any black jumper harness wire to GD161
(BK-YE).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2008-2009 Fusion / Milan / MKZ
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information >
Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality
> Page 8325
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 11)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C913. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP02 (GN) and GD139 (BK-YE) from C913.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP02 (GN) and any black jumper harness wire to GD139 (BK-YE).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2008-2009 Taurus / Sable / Taurus X
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 12)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner to
run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information >
Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality
> Page 8326
5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMN02 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C925. Cut the
three circuits on the female side of the connector
(17K745 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C925.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to
RMN02 (VT-BN) and DMN07 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2009 MKS
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 13)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and out the front of the headliner
above the rear view mirror.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124-1 for
links to location and connector views.
6. Identify circuits VMNO2 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C911. Pull back
the black harness sleeve and cut the three
circuits near C91 1 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2
access cover and cut circuits under trim cover. Refer to WSM, Section 417-01 for additional
information.
7. Identify circuits CBP41 (BU) and GD133 (BK) from C911.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information >
Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality
> Page 8327
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to
RMN02 (VT-BN) and DMN07 (shield).
^ Only splice into the wires heading away from the connector. The wires heading into the connector
(mirror) are no longer used.
^ Ensure the wiring is neatly routed from the splice locations into the headliner, following the
existing wire harness routing from mirror to headliner.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
OTHER APPLICABLE ARTICLES: 08-21-2
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
MT091305 Claim Diagnosis And Labor Actual
Performed As Actual Time. Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
17700 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-14-3 > Jul > 09 >
SYNC(R) System - Functions Inoperative/DTC's Set
Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - Functions
Inoperative/DTC's Set
TSB 09-14-3
07/27/09
SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY
DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED
FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge,
Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid,
Mariner
ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist
and Vehicle Health Report, may exhibit all or most of the following symptoms:
^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface
Module (APIM)
^ SYNC display menus/options blank
^ USB port inoperative
^ No SYNC Blue Tooth device connectivity
^ Voice/Phone/OK steering wheel controls inoperative
^ Lack of APIM communication
^ Parasitic battery draw with APIM connected
These symptoms may be triggered by a low battery state of charge, or a recent battery
disconnect/reconnect.
ACTION Follow the service procedure to correct the condition.
SERVICE PROCEDURE
This software upgrade only applies to the following Accessory Protocol Interface Module (APIM)
Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels:
^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC
^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD
^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD
To determine the current APIM software level, reference the Professional Technician Society (PTS)
website, enter the VIN in OASIS, click the GO
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-14-3 > Jul > 09 >
SYNC(R) System - Functions Inoperative/DTC's Set > Page 8333
button and select the SYNC button.
1. Determine if communication can be established with the APIM using IDS.
a. If communication cannot be verified, proceed to Step 2.
b. If communication is present, proceed to Step 3.
2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if
communication can be established. If not, perform
an APIM power reset by disconnecting and reconnecting the vehicle battery.
a. If communication is now present, proceed to Step 3.
b. If communication still cannot be established, replace the APIM.
3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure.
NOTE
SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE
THROUGH THE SYNCMYRIDE.COM WEBSITE.
NOTE
CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS
APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID
AND PASSWORD.
a. Connect the vehicle communication module (VCM) to the data link connector (DLC).
b. Connect the VCM to the IDS tool or laptop running IDS software.
c. Turn the ignition key to the on position.
d. Launch IDS tool.
e. If required, update the VCM with the latest software.
f. Close the IDS tool.
g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle
communication is established, press the GO
button.
h. From the Vehicle Service Session screen, Select the SYNC button.
i. Press read APIM button.
j. Select software and press program APIM to update the SYNC module.
NOTE
YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER
CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP.
NOTE
DO NOT USE A TRANSFER TYPE CABLE.
NOTE
DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING.
NOTE
THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW
THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY
INCLUDED IN WINDOWS XP.
k. Program the processor in the APIM.
l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the
IDS tool or laptop running IDS software, and to the vehicle USB port.
m. Follow the on-screen instructions to program the VIP module.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-14-3 > Jul > 09 >
SYNC(R) System - Functions Inoperative/DTC's Set > Page 8334
n. At the end of the configuration and programming procedure, the programming has been
completed successfully screen will be displayed.
o. Exit PTS, disconnect the VCM and disconnect the USB cable.
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
MT091403 Use SLTS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor Performed As Actual Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14D212 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality
Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - Poor Cell Phone
Sound Quality
TSB 09-13-5
07/13/09
SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE
RECOGNITION DIFFICULTIES WHILE DRIVING
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009
Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner
ISSUE Some customers of 2008-2009 SYNC equipped vehicles may express concern with their
call sound quality while using the SYNC microphone, complaints of excessive background noise
during a phone call, and/or issues with voice recognition accuracy while driving.
ACTION Follow the service procedure to correct the condition.
SERVICE PROCEDURE
The following service procedure involves updating the Accessory Protocol Interface Module (APIM)
software level and installing an external alternate SYNC microphone attached to the headliner.
NOTE
THIS PROCEDURE DOES NOT APPLY TO DEALER-INSTALLED SYNC SYSTEMS.
Do not perform Step 1 if vehicle is already equipped with SYNC 2.0 (911 and Vehicle Health
Report) or has been upgraded to consumer interface processor (CIP) level 9L3T-14D544-AE. To
determine the current APIM software level, Refer to the Professional Technician Society (PTS)
website, enter the VIN in OASIS, click the GO button, and select the SYNC button.
1. Reprogram the APIM to CIP software level 9L3T-14D544-AE. For additional information Refer to
other SYNC TSB's and WSM, Section 418-01.
Service Pack files may also be obtained at www.syncmyride.com.
When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to
test VR functionality while the vehicle is parked. If customer concerns are still present, this
procedure will not yield an improvement, and the service procedure should not be performed.
Instead, Refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to
assist customer.
The VR experience can be improved with user training and making improvements to the phone
book entries (longer entries make the system more robust). Ensure the customer does not try to
speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce
system effectiveness.
When diagnosing a concern related to call sound quality, expect marginal improvements for calls
described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints
where the call audio seems to drop out intermittently.
NOTE
THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO
THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO
NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING
WITH MICROPHONE INSTALLATION.
2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone
directly to the headliner and splicing in a jumper
harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be
functional.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 8339
a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone
installation and wire splicing locations. Refer to
Wiring Diagram (WD), Section 5-1 for recommended splicing methods.
b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or
functionality.
c. The microphone is directional. Make sure the microphone is always positioned so wire length is
minimized from view. When installing the
microphone adjacent to trim, place microphone as close to trim as possible to help minimize visible
wire.
2008-2009 Edge / MKX
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 1)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable up through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124-1 for
links to location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C211. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C210.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
cut wire ends heading up the A-pillar as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2009 Escape / Mariner
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 8340
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration (Figures 2 and 3). Firmly
press the microphone into place. Ensure the microphone is parallel and adjacent to overhead
console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an
overhead console. Proceed to Step 5 if not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 501-05 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner to
run microphone cable.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C214. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP41 (BU) and GD182 (BK-GY) from C214.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD1 82 (BK-GY).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
cut wire ends heading up the A-pillar as they are no longer used.
9. Connect the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2008-2009 Navigator / 2009 Expedition
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 8341
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figures 4 and 5)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or
positioned directly above A-pillar on headliner if not
equipped with an overhead console.
^ Proceed to Step 5 if not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online
WD, Section 124-1 for links to location and connector
views.
6. Identify circuits VMN07 (GY), RMN07 (VT), and DMN07 (shield - BK) from C298. Cut the three
circuits on the male side of the connector
(17C712 harness).
7. Identify circuits CBP31 (BU-OG) and GD133 (BK) from C298 (2008 Navigator only). Identify
circuits CBP41 (BU) and GD133 (BK) from C298
(2009 Expedition/Navigator only).
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP31 (BU-OG) and any black jumper harness wire to GD133 (BK)
for 2008 Navigator only. Blue jumper harness wire to CBP41 (BU) and any black jumper harness
wire to GD133 (BK) for 2009 Expedition/Navigator only.
^ Ensure original circuits remain connected in splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 8342
^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07
(VT) and DMN07 (shield - BK).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Connect the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the headliner.
2008-2009 Explorer / Explorer Sport Trac / Mountaineer
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 6)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner run
microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify and cut circuits VMNO7 (GY), RMNO7 (VT), and DMNO7 (shield) from C248. Cut the
three circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP05 (YE) and GD143 (BK-VT) from C248.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP05 (YE) and any black jumper harness wire to GD143 (BK-VT).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07
(VT) and DMN07 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
cut wire ends heading up the A-pillar as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2009 F-150
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 8343
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 7)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp.
2. Lower the overhead console or front lamp. Refer to WSM, Section 417-02 for additional
information.
3. Route microphone cable through existing hole in the headliner, and temporarily tuck excess wire
into headliner to the rear of the console or lamp.
4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or
front lamp trim directly behind microphone as
shown.
5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD,
Section 124-1 for links to location and connector
views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C314. Cut the three
circuits on the female side of the connector
(14358 harness).
7. Identify circuits CBP41 (BU) from C315 and GD133 (BK) from C314.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the headliner.
2009 F-Super Duty
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 8344
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 8)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
c. This repair is not recommended for vehicles not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield - BK) from C264. Cut the
three circuits on the female side of the connector
(17K745 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C264.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield - BK).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Connect the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2009 Flex
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 8345
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 9)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C925. Cut the three
circuits on the female side of the connector (14334 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C925.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2008-2009 Focus
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 8346
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration (Figure 10). Firmly press
the microphone into place. Ensure the microphone is parallel and adjacent to the dome lamp trim.
2. Lower the dome lamp assembly. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable up through existing hole in the headliner, and over to the passenger
side A-pillar. It may be necessary to slightly drop
headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install dome lamp assembly; ensure microphone cable enters the dome lamp trim directly behind
microphone as shown.
5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector
views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C934. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CPL60 (BN-YE) and GD161 (BK-YE) from C934.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CPL60 (BN-YE) and any black jumper harness wire to GD161
(BK-YE).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2008-2009 Fusion / Milan / MKZ
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 8347
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 11)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C913. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP02 (GN) and GD139 (BK-YE) from C913.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP02 (GN) and any black jumper harness wire to GD139 (BK-YE).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2008-2009 Taurus / Sable / Taurus X
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 12)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner to
run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 8348
5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMN02 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C925. Cut the
three circuits on the female side of the connector
(17K745 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C925.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to
RMN02 (VT-BN) and DMN07 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2009 MKS
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 13)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and out the front of the headliner
above the rear view mirror.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124-1 for
links to location and connector views.
6. Identify circuits VMNO2 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C911. Pull back
the black harness sleeve and cut the three
circuits near C91 1 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2
access cover and cut circuits under trim cover. Refer to WSM, Section 417-01 for additional
information.
7. Identify circuits CBP41 (BU) and GD133 (BK) from C911.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 >
SYNC(R) System - Poor Cell Phone Sound Quality > Page 8349
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to
RMN02 (VT-BN) and DMN07 (shield).
^ Only splice into the wires heading away from the connector. The wires heading into the connector
(mirror) are no longer used.
^ Ensure the wiring is neatly routed from the splice locations into the headliner, following the
existing wire harness routing from mirror to headliner.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
OTHER APPLICABLE ARTICLES: 08-21-2
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
MT091305 Claim Diagnosis And Labor Actual
Performed As Actual Time. Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
17700 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 >
SYNC(R) System - 911 Assist VHR Software Upgrade
Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - 911 Assist VHR
Software Upgrade
TSB 09-11-8
06/15/09
SYNC WITH 911 ASSIST AND VEHICLE HEALTH REPORT (VHR) DEALER UPGRADE
SOFTWARE
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009
Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner
This article supersedes TSB 9-5-4 to update the Service Procedure and add a production fix date.
ISSUE Some customers with 2008 or 2009 vehicles equipped with SYNC may request the 911
assist and vehicle health report (VHR) service upgrade installation. This software upgrade is not a
warrantable repair. Software is available only through professional technician society (PTS)
website, and not available through the syncmyride.com website.
ACTION Follow the Service Procedure steps to upgrade the SYNC software.
SERVICE PROCEDURE
This software upgrade applies only to the following vehicle model years and build dates:
^ 2008-2009 Focus built before 1/20/2009
^ 2008-2009 Explorer, Explorer Sport Trac, Mountaineer built before 1/12/2009
^ 2008-2009 Edge, MKX, and 2009 Flex, Escape, Mariner built before 12/4/2008
^ 2008-2009 Taurus, Taurus X, Sable, and 2009 F-Super Duty, MKS, F-150 built before 12/1/2008
^ 2008-2009 Fusion, Milan, MKZ
Vehicles built on or after these dates are already equipped with the 911 Assist/Vehicle Health
Report features and do not require updating.
To determine if the vehicles are within these build ranges or have already been upgraded to SYNC
911 Assist/VHR, access the Professional Technician Society (PTS) website, run OASIS by
pressing the Read VIN and DTC's button, and click on the SYNC tab. If the description box
indicates 911 and Vehicle Health Report, vehicle has been upgraded.
The 911 assist with VHR upgrade automatically reprograms the accessory protocol interface
module (APIM), instrument cluster (IC), and restraints control module (RCM).
The VHR applies only to United States (US) vehicles, 911 assist is for US and Canadian vehicles
operated within the US and Canada.
Performing this upgrade may result in some untested devices losing certain functionality, such as
bluetooth connection and phonebook download. Before continuing with this upgrade, make sure
the customer's device is listed on the compatibility matrix. It is strongly recommended to pair the
device to another vehicle currently equipped with 911 Assist/Vehicle Health Report to ensure
proper functionality before continuing.
Configuration and programming requires the use of IDS and a special PTS application. Installer
must have access to PTS and have a valid PTS user ID and password. Ensure the IDS is at the
latest software version.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 >
SYNC(R) System - 911 Assist VHR Software Upgrade > Page 8354
For additional programming tips, dealer network setting requirements, and possible error states
related to 911 Assist and VHR upgrades, reference the latest information on the Professional
Technician Society (PTS) website.
1. When updating 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator
vehicles, it is necessary to manually record and
reenter the Oil Life % Value as displayed on the message center. Record the current oil life before
updating 911 Assist/VHR, and reenter using the message center once programming is complete.
2. Connect the vehicle communication module (VCM) to the data link connector (DLC).
3. Connect the VCM to the IDS tool or laptop running IDS software.
4. Turn the ignition key to the on position.
5. Launch IDS tool but do not start a new session.
6. If required, update the VCM with the latest IDS release 59.9 and higher.
7. Close the IDS tool.
8. From the P15 website, run OASIS by pressing the read VIN and DTC's button. After vehicle
communication is established, press the go button.
9. From the Vehicle Service Session screen, select the Upgrade/Mods tab.
10. Once correct vehicle is chosen, select SYNC upgrade with 911 Assist/VHR.
11. Follow the on-screen instructions to program the APIM, IC, and RCM.
NOTE
TO COMPLETE THE UPGRADE PROCESS PERFORM THE FOLLOWING STEPS TO CONFIRM
THE VEHICLE HAS BEEN CORRECTLY CONFIGURED TO HAVE THESE FEATURES. FAILING
TO COMPLETE THE STEPS BELOW MAY RESULT IN 911 ASSIST/VHR NOT DISPLAYING ON
THE SYNC MENU.
12. Set ignition to off.
13. Open and close driver side door.
14. Set ignition to on.
15. Follow applicable instructions (see below) to ensure 911 Assist/VHR appear on Sync menu.
16. Close all Internet Explorer browser windows.
17. Clear all DTC's on all modules.
18. Reenter the Oil Life % Value for 2008-2009 Explorer, Mountaineer, Explorer Sport Trac,
Expedition, or Navigator vehicles.
Navigation Radio Instructions
911 Assist/VHR feature confirmation.
1. Press phone button on the Navigation LCD to enter phone menu.
2. Press cancel when pop-up menu appears on Navigation LCD display.
3. Press settings soft key on Navigation LCD display.
4. Press advanced soft key on Navigation LCD display.
5. Verify 911 Assist/VHR is in menu in Navigation LCD display.
Non Navigation Radio Instructions
911 Assist/VHR feature confirmation.
1. Press phone button on steering wheel.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 >
SYNC(R) System - 911 Assist VHR Software Upgrade > Page 8355
2. Press left arrow on steering wheel until return is displayed on radio screen, then press ok.
3. Press left arrow on steering wheel until return is displayed on radio screen, then press ok.
4. Press left arrow until 911 Assist/VHR is displayed.
Once 911 Assist/VHR installation is complete, the customer will need to reload their phone book if
that application is desired.
NOTE
IF SERVICE IS REQUIRED ON 2008 OR 2009 EARLY BUILT VEHICLES UPGRADED TO 911
ASSIST/VHR, REFERENCE THE APPLICABLE 2009 WORKSHOP MANUAL AND FOLLOW THE
V2 DIAGNOSTIC PROCEDURES.
WARRANTY STATUS: Information Only - Not Warrantable
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R)
System - 911 Assist VHR Software Upgrade
Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - 911 Assist VHR
Software Upgrade
TSB 09-11-8
06/15/09
SYNC WITH 911 ASSIST AND VEHICLE HEALTH REPORT (VHR) DEALER UPGRADE
SOFTWARE
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009
Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner
This article supersedes TSB 9-5-4 to update the Service Procedure and add a production fix date.
ISSUE Some customers with 2008 or 2009 vehicles equipped with SYNC may request the 911
assist and vehicle health report (VHR) service upgrade installation. This software upgrade is not a
warrantable repair. Software is available only through professional technician society (PTS)
website, and not available through the syncmyride.com website.
ACTION Follow the Service Procedure steps to upgrade the SYNC software.
SERVICE PROCEDURE
This software upgrade applies only to the following vehicle model years and build dates:
^ 2008-2009 Focus built before 1/20/2009
^ 2008-2009 Explorer, Explorer Sport Trac, Mountaineer built before 1/12/2009
^ 2008-2009 Edge, MKX, and 2009 Flex, Escape, Mariner built before 12/4/2008
^ 2008-2009 Taurus, Taurus X, Sable, and 2009 F-Super Duty, MKS, F-150 built before 12/1/2008
^ 2008-2009 Fusion, Milan, MKZ
Vehicles built on or after these dates are already equipped with the 911 Assist/Vehicle Health
Report features and do not require updating.
To determine if the vehicles are within these build ranges or have already been upgraded to SYNC
911 Assist/VHR, access the Professional Technician Society (PTS) website, run OASIS by
pressing the Read VIN and DTC's button, and click on the SYNC tab. If the description box
indicates 911 and Vehicle Health Report, vehicle has been upgraded.
The 911 assist with VHR upgrade automatically reprograms the accessory protocol interface
module (APIM), instrument cluster (IC), and restraints control module (RCM).
The VHR applies only to United States (US) vehicles, 911 assist is for US and Canadian vehicles
operated within the US and Canada.
Performing this upgrade may result in some untested devices losing certain functionality, such as
bluetooth connection and phonebook download. Before continuing with this upgrade, make sure
the customer's device is listed on the compatibility matrix. It is strongly recommended to pair the
device to another vehicle currently equipped with 911 Assist/Vehicle Health Report to ensure
proper functionality before continuing.
Configuration and programming requires the use of IDS and a special PTS application. Installer
must have access to PTS and have a valid PTS user ID and password. Ensure the IDS is at the
latest software version.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R)
System - 911 Assist VHR Software Upgrade > Page 8361
For additional programming tips, dealer network setting requirements, and possible error states
related to 911 Assist and VHR upgrades, reference the latest information on the Professional
Technician Society (PTS) website.
1. When updating 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator
vehicles, it is necessary to manually record and
reenter the Oil Life % Value as displayed on the message center. Record the current oil life before
updating 911 Assist/VHR, and reenter using the message center once programming is complete.
2. Connect the vehicle communication module (VCM) to the data link connector (DLC).
3. Connect the VCM to the IDS tool or laptop running IDS software.
4. Turn the ignition key to the on position.
5. Launch IDS tool but do not start a new session.
6. If required, update the VCM with the latest IDS release 59.9 and higher.
7. Close the IDS tool.
8. From the P15 website, run OASIS by pressing the read VIN and DTC's button. After vehicle
communication is established, press the go button.
9. From the Vehicle Service Session screen, select the Upgrade/Mods tab.
10. Once correct vehicle is chosen, select SYNC upgrade with 911 Assist/VHR.
11. Follow the on-screen instructions to program the APIM, IC, and RCM.
NOTE
TO COMPLETE THE UPGRADE PROCESS PERFORM THE FOLLOWING STEPS TO CONFIRM
THE VEHICLE HAS BEEN CORRECTLY CONFIGURED TO HAVE THESE FEATURES. FAILING
TO COMPLETE THE STEPS BELOW MAY RESULT IN 911 ASSIST/VHR NOT DISPLAYING ON
THE SYNC MENU.
12. Set ignition to off.
13. Open and close driver side door.
14. Set ignition to on.
15. Follow applicable instructions (see below) to ensure 911 Assist/VHR appear on Sync menu.
16. Close all Internet Explorer browser windows.
17. Clear all DTC's on all modules.
18. Reenter the Oil Life % Value for 2008-2009 Explorer, Mountaineer, Explorer Sport Trac,
Expedition, or Navigator vehicles.
Navigation Radio Instructions
911 Assist/VHR feature confirmation.
1. Press phone button on the Navigation LCD to enter phone menu.
2. Press cancel when pop-up menu appears on Navigation LCD display.
3. Press settings soft key on Navigation LCD display.
4. Press advanced soft key on Navigation LCD display.
5. Verify 911 Assist/VHR is in menu in Navigation LCD display.
Non Navigation Radio Instructions
911 Assist/VHR feature confirmation.
1. Press phone button on steering wheel.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R)
System - 911 Assist VHR Software Upgrade > Page 8362
2. Press left arrow on steering wheel until return is displayed on radio screen, then press ok.
3. Press left arrow on steering wheel until return is displayed on radio screen, then press ok.
4. Press left arrow until 911 Assist/VHR is displayed.
Once 911 Assist/VHR installation is complete, the customer will need to reload their phone book if
that application is desired.
NOTE
IF SERVICE IS REQUIRED ON 2008 OR 2009 EARLY BUILT VEHICLES UPGRADED TO 911
ASSIST/VHR, REFERENCE THE APPLICABLE 2009 WORKSHOP MANUAL AND FOLLOW THE
V2 DIAGNOSTIC PROCEDURES.
WARRANTY STATUS: Information Only - Not Warrantable
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack,
Entertainment System > Component Information > Diagrams
C3312
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack,
Entertainment System > Component Information > Diagrams > Page 8367
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 (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Locations
DVD Player: Locations
View 151-36
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Locations > Page 8371
View 151-37
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Locations > Page 8372
C9029
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control
Module > Component Information > Technical Service Bulletins > Customer Interest for Entertainment System Control
Module: > 10-9-7 > May > 10 > Audio System - Unexpected CD Shuffle With Key Off
Entertainment System Control Module: Customer Interest Audio System - Unexpected CD Shuffle
With Key Off
TSB 10-9-7
05/24/10
UNEXPECTED COMPACT DISC SHUFFLE OR CYCLING DURING NORMAL RADIO
OPERATION OR WITH THE KEY OFF - NON-NAVIGATION RADIOS ONLY
FORD: 2008-2010 Expedition, Explorer Sport Trac, Explorer
MERCURY: 2008-2010 Mountaineer
ISSUE Some 2008-2010 Expedition, Explorer, Explorer Sport Trac and Mountaineer vehicles
equipped with a non-navigation CD-6 Audio Control Module (ACM) may experience an unexpected
Compact Disc (CD) shuffle or cycling during start up, during normal ACM operation, or shutting off
the vehicle.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
This service procedure affects non-navigation radios only. If you attempt to run module
reprogramming on the 2008-2010 ACM and the service tool does not recognize the part numbers
of the ACM currently installed, this procedure does not apply.
Reprogram the ACM to the latest calibration using IDS release 66.05A and higher. This new
calibration is not included in the VCM 2010. Version A 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
100907A 2008-2010 Expedition, 0.3 Hr.
Explorer, Mountaineer, And Explorer Sport Trac: Reprogram The Audio Control Module (Do Not
Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Entertainment System
Control Module: > 10-9-7 > May > 10 > Audio System - Unexpected CD Shuffle With Key Off
Entertainment System Control Module: All Technical Service Bulletins Audio System - Unexpected
CD Shuffle With Key Off
TSB 10-9-7
05/24/10
UNEXPECTED COMPACT DISC SHUFFLE OR CYCLING DURING NORMAL RADIO
OPERATION OR WITH THE KEY OFF - NON-NAVIGATION RADIOS ONLY
FORD: 2008-2010 Expedition, Explorer Sport Trac, Explorer
MERCURY: 2008-2010 Mountaineer
ISSUE Some 2008-2010 Expedition, Explorer, Explorer Sport Trac and Mountaineer vehicles
equipped with a non-navigation CD-6 Audio Control Module (ACM) may experience an unexpected
Compact Disc (CD) shuffle or cycling during start up, during normal ACM operation, or shutting off
the vehicle.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
This service procedure affects non-navigation radios only. If you attempt to run module
reprogramming on the 2008-2010 ACM and the service tool does not recognize the part numbers
of the ACM currently installed, this procedure does not apply.
Reprogram the ACM to the latest calibration using IDS release 66.05A and higher. This new
calibration is not included in the VCM 2010. Version A 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
100907A 2008-2010 Expedition, 0.3 Hr.
Explorer, Mountaineer, And Explorer Sport Trac: Reprogram The Audio Control Module (Do Not
Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control
Panel > Component Information > Service and Repair
Entertainment System Control Panel: Service and Repair
REAR ENTERTAINMENT MODULE (RETM)
Removal
NOTE: Programmable module installation (PMI) only needs to be carried out if the rear
entertainment module (RETM) player is being replaced.
1. Upload the RETM configuration to the scan tool.
2. NOTE: Open the RETM display.
Remove the 4 screws.
3. Remove the RETM.
- Pull down on the sides of the RETM 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 RETM on the J-hooks and disconnect the electrical connector.
- Remove the RETM from the J-hooks.
Installation
1. Hang the RETM on the J-hooks. 2. Connect the electrical connector. 3. Remove the RETM from
the J-hooks.
4. NOTE: Tilt the RETM, as necessary, to align it correctly.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control
Panel > Component Information > Service and Repair > Page 8389
Align the left side guide pin with the left side locating hole.
5. Lift up the right side of the RETM and engage the U-hooks. 6. Install the 4 screws. 7. Push on
the left and right sides of the RETM to engage the clips. 8. Download the RETM configuration from
the scan tool.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Locations
View 151-36
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Locations > Page 8393
C928
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Locations > Page 8394
Garage Door Opener Transmitter: Description and Operation
UNIVERSAL TRANSMITTER
The universal transmitter is an integral part of the overhead console and 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 (V8-4.6L (2008))
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 for obvious signs of electrical damage.
VISUAL INSPECTION CHART
Electrical Wiring, terminals or connectors
- 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 and
GO to Symptom Chart. See: Symptom Related Diagnostic Procedures
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8397
Symptom Chart
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8398
Garage Door Opener Transmitter: Pinpoint Tests
PINPOINT TEST A: THE UNIVERSAL TRANSMITTER IS INOPERATIVE
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 from the battery saver relay in the smart junction box (SJB) to the
universal transmitter through circuit CLN01 (GN/VT) and the universal transmitter is grounded on
circuit GD133 (BK).
This pinpoint test is intended to diagnose the following:
- Wiring, terminals or connectors
- Universal transmitter
- Receiver unit
A1-A4
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8399
A4 Continued
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8400
Garage Door Opener Transmitter: Programming and Relearning
UNIVERSAL TRANSMITTER PROGRAMMING
NOTE: A new battery in the hand-held transmitter may allow quicker and easier training due to a
more accurate transmission of the radio frequency signal.
1. Verify the hand-held transmitter is operative. 2. Turn the key to the ON position. 3. 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.
4. Select 1 of the 3 universal transmitter buttons to be used for programming. 5. Hold the end of the
hand-held transmitter 25-76 mm (1-3 in) away from the front surface of the universal transmitter so
that the universal
transmitter red light can still be seen.
6. 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 with this type of hand-held transmitter, continue
to hold the button on the universal transmitter while pressing and releasing the hand-held
transmitter button every 2 seconds.
At the same time, press the hand-held transmitter button and the desired button on the universal
transmitter until the red light on the universal transmitter flashes first slowly, and then rapidly.
Release both buttons when the rapid flashing begins.
7. Firmly press and hold for 5 seconds, then release the just-trained universal transmitter button up
to 2 separate times to activate the door. If after 2
separate times, the door still does not activate, press and hold the just-trained universal transmitter
button and observe the indicator light. If the indicator light stays on constantly, programming is complete and the device should activate
when the universal transmitter button is pressed and released.
- If the indicator light blinks rapidly for 2 seconds and then turns to a constant light, follow the
Training a Garage Door Opener Equipped With "Rolling Codes" procedure to complete the
programming of a rolling code equipped device.
Training a Garage Door Opener Equipped With "Rolling Codes"
1. At the garage door opener receiver (motor-head unit) in the garage, locate the "learn" or "smart"
button. This can usually be found where the
hanging antenna wire is attached to the motor-head unit.
2. Firmly press and release the "learn" or "smart" button. (The name and color of the button may
vary by manufacturer.) There are 30 seconds to
initiate step 3.
3. Return to the vehicle and firmly press, hold for 2 seconds and release the programmed universal
transmitter button. Repeat the press/hold/release
sequence a second time, and depending on the brand of the garage door opener (or other rolling
code equipped device), repeat this sequence a third time to complete the programming process.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Testing and Inspection > Page 8401
Special Tool(s)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System
Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module:
> 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns
Global Positioning System Module: Customer Interest SYNC(R) System - Software Update For
Various Concerns
TSB 09-26-8
01/04/10
SYNC SOFTWARE UPDATE - VARIOUS ISSUES
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009
Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner
This article supersedes TSB 9-22-14 to update the Service Procedure.
ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following
symptoms:
^ Universal Serial Bus (USB) port inoperative.
^ USB audio muting when using various non-Apple USB devices.
^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands.
^ Excessive background noise and/or poor voice sound quality.
^ Phone book auto download inoperative on supported devices.
^ SYNC steering wheel control (SWC) switches being inoperative intermittently.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace
processor (CIP) software levels.
^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report)
^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health
Report)
Service Pack files may be obtained at www.syncmyride.com.
Reprogram the APIM
Contains software fix updates for the following:
^ Phone book auto download inoperative.
^ USB audio muting.
^ SYNC steering wheel control (SWC) switches being inoperative.
^ Voice recognition on 2-digit entries.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System
Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module:
> 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 8411
^ USB port inoperative with diagnostic trouble code (DTC) B1342.
^ Poor call sound quality.
This software update also contains enhancements that will improve the reliability of both Bluetooth
and USB connections to SYNC(R) from various consumer devices, and microphone enhancements
to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The
Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple
call handling and other mobile phone features. The USB enhancements improve support for media
players and the playing of file formats and podcasts.
NOTE
REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC
SOFTWARE PROGRAMMING TIPS.
1. Connect the vehicle communication module (VCM) to the data link connector (DLC).
2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software.
3. Turn the ignition key to the on position.
4. Launch IDS tool.
5. If required, update the VCM with the latest software.
6. Close the IDS tool.
7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle
communication is established, press the GO button.
8. From the Vehicle Service Session screen, Select the SYNC button.
9. Press read APIM button.
10. Select software and press program APIM to update the SYNC module.
NOTE
YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER
CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP.
NOTE
DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING.
NOTE
THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW
THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY
INCLUDED IN WINDOWS XP.
11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP).
NOTE
DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE.
a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the
IDS tool or laptop running IDS software and
to the vehicle USB port.
b. Follow the on-screen instructions to program both processors on the Sync module (VIP and
CIP).
12. At the end of the configuration and programming procedure, the programming has been
completed successfully screen will be displayed.
13. Exit PTS, disconnect the VCM and disconnect the USB cable.
OTHER APPLICABLE ARTICLES: 08-21-02
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
092608A 2008-2009 Edge, Explorer, 0.4 Hr.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System
Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module:
> 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 8412
Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus,
Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty,
Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14D212 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning
System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns
Global Positioning System Module: All Technical Service Bulletins SYNC(R) System - Software
Update For Various Concerns
TSB 09-26-8
01/04/10
SYNC SOFTWARE UPDATE - VARIOUS ISSUES
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009
Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner
This article supersedes TSB 9-22-14 to update the Service Procedure.
ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following
symptoms:
^ Universal Serial Bus (USB) port inoperative.
^ USB audio muting when using various non-Apple USB devices.
^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands.
^ Excessive background noise and/or poor voice sound quality.
^ Phone book auto download inoperative on supported devices.
^ SYNC steering wheel control (SWC) switches being inoperative intermittently.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace
processor (CIP) software levels.
^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report)
^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health
Report)
Service Pack files may be obtained at www.syncmyride.com.
Reprogram the APIM
Contains software fix updates for the following:
^ Phone book auto download inoperative.
^ USB audio muting.
^ SYNC steering wheel control (SWC) switches being inoperative.
^ Voice recognition on 2-digit entries.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning
System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 8418
^ USB port inoperative with diagnostic trouble code (DTC) B1342.
^ Poor call sound quality.
This software update also contains enhancements that will improve the reliability of both Bluetooth
and USB connections to SYNC(R) from various consumer devices, and microphone enhancements
to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The
Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple
call handling and other mobile phone features. The USB enhancements improve support for media
players and the playing of file formats and podcasts.
NOTE
REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC
SOFTWARE PROGRAMMING TIPS.
1. Connect the vehicle communication module (VCM) to the data link connector (DLC).
2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software.
3. Turn the ignition key to the on position.
4. Launch IDS tool.
5. If required, update the VCM with the latest software.
6. Close the IDS tool.
7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle
communication is established, press the GO button.
8. From the Vehicle Service Session screen, Select the SYNC button.
9. Press read APIM button.
10. Select software and press program APIM to update the SYNC module.
NOTE
YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER
CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP.
NOTE
DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING.
NOTE
THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW
THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY
INCLUDED IN WINDOWS XP.
11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP).
NOTE
DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE.
a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the
IDS tool or laptop running IDS software and
to the vehicle USB port.
b. Follow the on-screen instructions to program both processors on the Sync module (VIP and
CIP).
12. At the end of the configuration and programming procedure, the programming has been
completed successfully screen will be displayed.
13. Exit PTS, disconnect the VCM and disconnect the USB cable.
OTHER APPLICABLE ARTICLES: 08-21-02
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
092608A 2008-2009 Edge, Explorer, 0.4 Hr.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning
System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 8419
Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus,
Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty,
Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14D212 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning
Module > Component Information > Locations
View 151-28
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning
Module > Component Information > Locations > Page 8424
Memory Positioning Module: Diagrams
C341A
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning
Module > Component Information > Locations > Page 8425
C341B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning
Module > Component Information > Locations > Page 8426
C341C
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning
Module > Component Information > Locations > Page 8427
Memory Positioning Module: Service and Repair
DRIVER SEAT MODULE (DSM)
Special Tool(s)
Special Tool(s)
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning
Module > Component Information > Locations > Page 8428
Part 2
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. NOTE: This step is necessary only if the DSM is being replaced.
Upload the module configuration information from the DSM.
2. Remove the driver seat. 3. Remove the 2 DSM screws. 4. Disconnect the electrical connectors
and remove the DSM.
5. NOTE: Once the module is installed (if it was replaced) 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 (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch >
Component Information > Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch >
Component Information > Locations > Page 8432
C2094
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component
Information > Technical Service Bulletins > Customer Interest: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update
For Various Concerns
Navigation Module: Customer Interest SYNC(R) System - Software Update For Various Concerns
TSB 09-26-8
01/04/10
SYNC SOFTWARE UPDATE - VARIOUS ISSUES
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009
Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner
This article supersedes TSB 9-22-14 to update the Service Procedure.
ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following
symptoms:
^ Universal Serial Bus (USB) port inoperative.
^ USB audio muting when using various non-Apple USB devices.
^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands.
^ Excessive background noise and/or poor voice sound quality.
^ Phone book auto download inoperative on supported devices.
^ SYNC steering wheel control (SWC) switches being inoperative intermittently.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace
processor (CIP) software levels.
^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report)
^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health
Report)
Service Pack files may be obtained at www.syncmyride.com.
Reprogram the APIM
Contains software fix updates for the following:
^ Phone book auto download inoperative.
^ USB audio muting.
^ SYNC steering wheel control (SWC) switches being inoperative.
^ Voice recognition on 2-digit entries.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component
Information > Technical Service Bulletins > Customer Interest: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update
For Various Concerns > Page 8442
^ USB port inoperative with diagnostic trouble code (DTC) B1342.
^ Poor call sound quality.
This software update also contains enhancements that will improve the reliability of both Bluetooth
and USB connections to SYNC(R) from various consumer devices, and microphone enhancements
to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The
Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple
call handling and other mobile phone features. The USB enhancements improve support for media
players and the playing of file formats and podcasts.
NOTE
REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC
SOFTWARE PROGRAMMING TIPS.
1. Connect the vehicle communication module (VCM) to the data link connector (DLC).
2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software.
3. Turn the ignition key to the on position.
4. Launch IDS tool.
5. If required, update the VCM with the latest software.
6. Close the IDS tool.
7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle
communication is established, press the GO button.
8. From the Vehicle Service Session screen, Select the SYNC button.
9. Press read APIM button.
10. Select software and press program APIM to update the SYNC module.
NOTE
YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER
CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP.
NOTE
DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING.
NOTE
THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW
THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY
INCLUDED IN WINDOWS XP.
11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP).
NOTE
DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE.
a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the
IDS tool or laptop running IDS software and
to the vehicle USB port.
b. Follow the on-screen instructions to program both processors on the Sync module (VIP and
CIP).
12. At the end of the configuration and programming procedure, the programming has been
completed successfully screen will be displayed.
13. Exit PTS, disconnect the VCM and disconnect the USB cable.
OTHER APPLICABLE ARTICLES: 08-21-02
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
092608A 2008-2009 Edge, Explorer, 0.4 Hr.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component
Information > Technical Service Bulletins > Customer Interest: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update
For Various Concerns > Page 8443
Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus,
Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty,
Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14D212 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-26-8 > Jan > 10 > SYNC(R) System Software Update For Various Concerns
Navigation Module: All Technical Service Bulletins SYNC(R) System - Software Update For
Various Concerns
TSB 09-26-8
01/04/10
SYNC SOFTWARE UPDATE - VARIOUS ISSUES
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009
Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner
This article supersedes TSB 9-22-14 to update the Service Procedure.
ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following
symptoms:
^ Universal Serial Bus (USB) port inoperative.
^ USB audio muting when using various non-Apple USB devices.
^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands.
^ Excessive background noise and/or poor voice sound quality.
^ Phone book auto download inoperative on supported devices.
^ SYNC steering wheel control (SWC) switches being inoperative intermittently.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace
processor (CIP) software levels.
^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report)
^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health
Report)
Service Pack files may be obtained at www.syncmyride.com.
Reprogram the APIM
Contains software fix updates for the following:
^ Phone book auto download inoperative.
^ USB audio muting.
^ SYNC steering wheel control (SWC) switches being inoperative.
^ Voice recognition on 2-digit entries.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-26-8 > Jan > 10 > SYNC(R) System Software Update For Various Concerns > Page 8449
^ USB port inoperative with diagnostic trouble code (DTC) B1342.
^ Poor call sound quality.
This software update also contains enhancements that will improve the reliability of both Bluetooth
and USB connections to SYNC(R) from various consumer devices, and microphone enhancements
to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The
Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple
call handling and other mobile phone features. The USB enhancements improve support for media
players and the playing of file formats and podcasts.
NOTE
REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC
SOFTWARE PROGRAMMING TIPS.
1. Connect the vehicle communication module (VCM) to the data link connector (DLC).
2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software.
3. Turn the ignition key to the on position.
4. Launch IDS tool.
5. If required, update the VCM with the latest software.
6. Close the IDS tool.
7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle
communication is established, press the GO button.
8. From the Vehicle Service Session screen, Select the SYNC button.
9. Press read APIM button.
10. Select software and press program APIM to update the SYNC module.
NOTE
YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER
CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP.
NOTE
DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING.
NOTE
THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW
THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY
INCLUDED IN WINDOWS XP.
11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP).
NOTE
DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE.
a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the
IDS tool or laptop running IDS software and
to the vehicle USB port.
b. Follow the on-screen instructions to program both processors on the Sync module (VIP and
CIP).
12. At the end of the configuration and programming procedure, the programming has been
completed successfully screen will be displayed.
13. Exit PTS, disconnect the VCM and disconnect the USB cable.
OTHER APPLICABLE ARTICLES: 08-21-02
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
092608A 2008-2009 Edge, Explorer, 0.4 Hr.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-26-8 > Jan > 10 > SYNC(R) System Software Update For Various Concerns > Page 8450
Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus,
Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty,
Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14D212 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Navigation Module: > 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 (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Navigation Module: > 09-1-6 > Jan > 09 > Brakes
- Poor Brake Pedal Feel > Page 8456
13480A, 9818A8)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2455 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Navigation Module: > 09-1-6 > Jan > 09 > Brakes
- Poor Brake Pedal Feel > Page 8462
13480A, 9818A8)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2455 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor >
Component Information > Locations
Pedal Positioning Motor: Locations
View 151-2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor >
Component Information > Locations > Page 8467
View 151-5
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor >
Component Information > Locations > Page 8468
Pedal Positioning Motor: Diagrams
C2003
C2159
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch >
Component Information > Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch >
Component Information > Locations > Page 8472
C2089
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound
System > Component Information > Diagrams
Amplifier: Diagrams
C466
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound
System > Component Information > Diagrams > Page 8477
C3041
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player
(CD) > Component Information > Technical Service Bulletins > Customer Interest for Compact Disc Player (CD): > 10-9-7 >
May > 10 > Audio System - Unexpected CD Shuffle With Key Off
Compact Disc Player (CD): Customer Interest Audio System - Unexpected CD Shuffle With Key Off
TSB 10-9-7
05/24/10
UNEXPECTED COMPACT DISC SHUFFLE OR CYCLING DURING NORMAL RADIO
OPERATION OR WITH THE KEY OFF - NON-NAVIGATION RADIOS ONLY
FORD: 2008-2010 Expedition, Explorer Sport Trac, Explorer
MERCURY: 2008-2010 Mountaineer
ISSUE Some 2008-2010 Expedition, Explorer, Explorer Sport Trac and Mountaineer vehicles
equipped with a non-navigation CD-6 Audio Control Module (ACM) may experience an unexpected
Compact Disc (CD) shuffle or cycling during start up, during normal ACM operation, or shutting off
the vehicle.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
This service procedure affects non-navigation radios only. If you attempt to run module
reprogramming on the 2008-2010 ACM and the service tool does not recognize the part numbers
of the ACM currently installed, this procedure does not apply.
Reprogram the ACM to the latest calibration using IDS release 66.05A and higher. This new
calibration is not included in the VCM 2010. Version A 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
100907A 2008-2010 Expedition, 0.3 Hr.
Explorer, Mountaineer, And Explorer Sport Trac: Reprogram The Audio Control Module (Do Not
Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player
(CD) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compact Disc Player
(CD): > 10-9-7 > May > 10 > Audio System - Unexpected CD Shuffle With Key Off
Compact Disc Player (CD): All Technical Service Bulletins Audio System - Unexpected CD Shuffle
With Key Off
TSB 10-9-7
05/24/10
UNEXPECTED COMPACT DISC SHUFFLE OR CYCLING DURING NORMAL RADIO
OPERATION OR WITH THE KEY OFF - NON-NAVIGATION RADIOS ONLY
FORD: 2008-2010 Expedition, Explorer Sport Trac, Explorer
MERCURY: 2008-2010 Mountaineer
ISSUE Some 2008-2010 Expedition, Explorer, Explorer Sport Trac and Mountaineer vehicles
equipped with a non-navigation CD-6 Audio Control Module (ACM) may experience an unexpected
Compact Disc (CD) shuffle or cycling during start up, during normal ACM operation, or shutting off
the vehicle.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
This service procedure affects non-navigation radios only. If you attempt to run module
reprogramming on the 2008-2010 ACM and the service tool does not recognize the part numbers
of the ACM currently installed, this procedure does not apply.
Reprogram the ACM to the latest calibration using IDS release 66.05A and higher. This new
calibration is not included in the VCM 2010. Version A 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
100907A 2008-2010 Expedition, 0.3 Hr.
Explorer, Mountaineer, And Explorer Sport Trac: Reprogram The Audio Control Module (Do Not
Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Remote Switch, Audio - Stereo > Component Information > Locations
View 151-16
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Remote Switch, Audio - Stereo > Component Information > Locations > Page 8495
C2208
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control,
Audio - Stereo > Component Information > Service and Repair
Remote Control: Service and Repair
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 (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 09-20-10 > Oct > 09 > Audio
System - Inoperative/Speaker Popping Noise
Speaker: Customer Interest Audio System - Inoperative/Speaker Popping Noise
TSB 09-20-10
10/19/09
SPEAKER POP AND/OR RADIO INOPERATIVE/BLANK/LOCKED UP
FORD: 2008-2009 Fusion, Mustang 2008 F-150 2008-2009 Edge, Expedition, Explorer Sport Trac,
Explorer, F-Super Duty
MERCURY: 2008-2009 Milan, Mountaineer
This article supersedes TSB 9-16-3 to update the vehicle lines.
ISSUE Some 2008-2009 F-Super Duty, Expedition, Explorer, Explorer Sport Trac, Mountaineer,
Fusion, Milan, Mustang,, Edge and 2008 F-150 vehicles equipped with Single CD and CDX6 Audio
Control Modules (ACM), may exhibit either a speaker pop noise and/or a condition where the ACM
is completely inoperative or will not power on.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
The speaker pop typically happens after an extended drive period when vehicle is warm and
opening/closing a door; however, it may happen anytime the (ACM) is turned off. Using the vehicle
heater through the instrument panel (IP) panel vents (on high setting) may also cause the condition
to repeat more often. The ACM may be completely inoperative, blank. or locked up. It may be
caused by a software lockup event within the ACM.
Reprogram the ACM to the latest calibration using IDS 63.02 and higher. This new calibration is not
included in the VCM 2009.9 DVD Calibration files may also be obtained at the website.
An ACM replacement will be necessary for 2008 F-150 for the above symptoms, it can not be
reprogrammed with IDS. Reference Workshop Manual, Section 415-00 for removal and installation
instructions. Please specify speaker pop noise/lock up on the 1878 form when ordering a
replacement ACM for F-150.
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
092010A 2008-2009 F-Super Duty, 0.3 Hr.
Expedition, Explorer, Mountaineer, Explorer Sport Trac, Edge, Fusion, Milan, Mustang: Reprogram
The ACM (Do Not Use With Any Other Labor Operations)
092010B 2008 F-150: Retrieve The 0.2 Hr.
ACM Unit Part Number - Acquire And Order An Exchange Unit Can Be Claimed with Operation C
(Do Not Use With Any Labor Operation Outside Of This Article)
092010C 2008 F-150: Replace The 0.4 Hr.
ACM, Can Be Claimed
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 09-20-10 > Oct > 09 > Audio
System - Inoperative/Speaker Popping Noise > Page 8507
with Operation B (Do Not Use With Any Labor Operation Outside Of This Article)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 09-20-10 > Oct > 09 >
Audio System - Inoperative/Speaker Popping Noise
Speaker: All Technical Service Bulletins Audio System - Inoperative/Speaker Popping Noise
TSB 09-20-10
10/19/09
SPEAKER POP AND/OR RADIO INOPERATIVE/BLANK/LOCKED UP
FORD: 2008-2009 Fusion, Mustang 2008 F-150 2008-2009 Edge, Expedition, Explorer Sport Trac,
Explorer, F-Super Duty
MERCURY: 2008-2009 Milan, Mountaineer
This article supersedes TSB 9-16-3 to update the vehicle lines.
ISSUE Some 2008-2009 F-Super Duty, Expedition, Explorer, Explorer Sport Trac, Mountaineer,
Fusion, Milan, Mustang,, Edge and 2008 F-150 vehicles equipped with Single CD and CDX6 Audio
Control Modules (ACM), may exhibit either a speaker pop noise and/or a condition where the ACM
is completely inoperative or will not power on.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
The speaker pop typically happens after an extended drive period when vehicle is warm and
opening/closing a door; however, it may happen anytime the (ACM) is turned off. Using the vehicle
heater through the instrument panel (IP) panel vents (on high setting) may also cause the condition
to repeat more often. The ACM may be completely inoperative, blank. or locked up. It may be
caused by a software lockup event within the ACM.
Reprogram the ACM to the latest calibration using IDS 63.02 and higher. This new calibration is not
included in the VCM 2009.9 DVD Calibration files may also be obtained at the website.
An ACM replacement will be necessary for 2008 F-150 for the above symptoms, it can not be
reprogrammed with IDS. Reference Workshop Manual, Section 415-00 for removal and installation
instructions. Please specify speaker pop noise/lock up on the 1878 form when ordering a
replacement ACM for F-150.
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
092010A 2008-2009 F-Super Duty, 0.3 Hr.
Expedition, Explorer, Mountaineer, Explorer Sport Trac, Edge, Fusion, Milan, Mustang: Reprogram
The ACM (Do Not Use With Any Other Labor Operations)
092010B 2008 F-150: Retrieve The 0.2 Hr.
ACM Unit Part Number - Acquire And Order An Exchange Unit Can Be Claimed with Operation C
(Do Not Use With Any Labor Operation Outside Of This Article)
092010C 2008 F-150: Replace The 0.4 Hr.
ACM, Can Be Claimed
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 09-20-10 > Oct > 09 >
Audio System - Inoperative/Speaker Popping Noise > Page 8513
with Operation B (Do Not Use With Any Labor Operation Outside Of This Article)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Speaker, Left Front
C523
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Speaker, Left Front > Page 8516
C612
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Speaker, Left Front > Page 8517
C702
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Speaker, Left Front > Page 8518
C802
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Page 8519
Speaker: Testing and Inspection
SPEAKER WALK-AROUND TEST
NOTE: To enter the speaker walk-around test or audio control module (ACM) self-diagnostic mode,
the audio system must be on and in radio tuner mode.
1. To enter the speaker walk-around test, simultaneously press preset buttons 3 and 6. 2. The
speaker walk-around test stops at each speaker and applies sound to each speaker for about 1-2
seconds. Each speaker is tested and displayed
on the ACM in the following sequence: RF, LF, LR, RR, and SUBWOOFER.
3. To exit the speaker walk-around test, turn the key OFF, turn the audio system off, or press
preset button 1 for diagnostics.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Service and Repair > Door Speaker > Page 8522
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8528
Accessory Delay Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest
for Communications Control Module: > 10-2-8 > Feb > 10 > SYNC(R) System - Defaults To 'Privacy Mode'
Communications Control Module: Customer Interest SYNC(R) System - Defaults To 'Privacy Mode'
TSB 10-2-8
02/15/10
SYNC SYSTEM DEFAULTS TO OR STAYS IN PRIVACY MODE, MULTIPLE VEHICLE LINES
FORD: 2008-2009 Taurus X 2008-2010 Focus, Fusion, Mustang, Taurus, Edge, Escape,
Expedition, Explorer Sport Trac, Explorer, F-150, F-250, F-350, F-450 2009-2010 Flex
LINCOLN: 2008-2010 MKZ 2009-2010 MKS 2008 Mark LT 2008-2010 MKX, Navigator 2010 MKT
MERCURY: 2008-2009 Sable 2008-2010 Milan, Mariner, Mountaineer
ISSUE Some customers of 2008-2010 SYNC-equipped vehicles may express concern with their
SYNC paired device defaulting, switching or staying on privacy mode. The customer may not be
able to accept the call through the SYNC system or must answer the call manually on their
personal device.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Set the Privacy mode to Off on the device and recheck Sync operation.
2. If necessary, test the device on another vehicle with the same version SYNC. If the concern is
still present, the device is the concern. Continue with
normal WSM Diagnostics.
NOTE
PRIVACY MODE MEANS THAT THE PHONE IS CONTROLLING THE AUDIO. SYNC ONLY
MAKES REQUESTS TO THE PHONE TO TRANSFER THIS RESPONSIBILITY OR AUDIO TO
SYNC. IF THE PHONE DOES NOT ACCEPT THIS REQUEST OR THERE IS A PROBLEM IN
THE COMMUNICATION TO MAKE THIS HAPPEN, YOU ARE BY DEFAULT IN PRIVACY MODE.
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest
for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns
Communications Control Module: Customer Interest SYNC(R) System - Software Update For
Various Concerns
TSB 09-26-8
01/04/10
SYNC SOFTWARE UPDATE - VARIOUS ISSUES
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009
Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner
This article supersedes TSB 9-22-14 to update the Service Procedure.
ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following
symptoms:
^ Universal Serial Bus (USB) port inoperative.
^ USB audio muting when using various non-Apple USB devices.
^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands.
^ Excessive background noise and/or poor voice sound quality.
^ Phone book auto download inoperative on supported devices.
^ SYNC steering wheel control (SWC) switches being inoperative intermittently.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace
processor (CIP) software levels.
^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report)
^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health
Report)
Service Pack files may be obtained at www.syncmyride.com.
Reprogram the APIM
Contains software fix updates for the following:
^ Phone book auto download inoperative.
^ USB audio muting.
^ SYNC steering wheel control (SWC) switches being inoperative.
^ Voice recognition on 2-digit entries.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest
for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns >
Page 8541
^ USB port inoperative with diagnostic trouble code (DTC) B1342.
^ Poor call sound quality.
This software update also contains enhancements that will improve the reliability of both Bluetooth
and USB connections to SYNC(R) from various consumer devices, and microphone enhancements
to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The
Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple
call handling and other mobile phone features. The USB enhancements improve support for media
players and the playing of file formats and podcasts.
NOTE
REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC
SOFTWARE PROGRAMMING TIPS.
1. Connect the vehicle communication module (VCM) to the data link connector (DLC).
2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software.
3. Turn the ignition key to the on position.
4. Launch IDS tool.
5. If required, update the VCM with the latest software.
6. Close the IDS tool.
7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle
communication is established, press the GO button.
8. From the Vehicle Service Session screen, Select the SYNC button.
9. Press read APIM button.
10. Select software and press program APIM to update the SYNC module.
NOTE
YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER
CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP.
NOTE
DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING.
NOTE
THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW
THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY
INCLUDED IN WINDOWS XP.
11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP).
NOTE
DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE.
a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the
IDS tool or laptop running IDS software and
to the vehicle USB port.
b. Follow the on-screen instructions to program both processors on the Sync module (VIP and
CIP).
12. At the end of the configuration and programming procedure, the programming has been
completed successfully screen will be displayed.
13. Exit PTS, disconnect the VCM and disconnect the USB cable.
OTHER APPLICABLE ARTICLES: 08-21-02
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
092608A 2008-2009 Edge, Explorer, 0.4 Hr.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest
for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns >
Page 8542
Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus,
Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty,
Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14D212 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest
for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set
Communications Control Module: Customer Interest SYNC(R) System - Functions
Inoperative/DTC's Set
TSB 09-14-3
07/27/09
SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY
DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED
FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge,
Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid,
Mariner
ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist
and Vehicle Health Report, may exhibit all or most of the following symptoms:
^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface
Module (APIM)
^ SYNC display menus/options blank
^ USB port inoperative
^ No SYNC Blue Tooth device connectivity
^ Voice/Phone/OK steering wheel controls inoperative
^ Lack of APIM communication
^ Parasitic battery draw with APIM connected
These symptoms may be triggered by a low battery state of charge, or a recent battery
disconnect/reconnect.
ACTION Follow the service procedure to correct the condition.
SERVICE PROCEDURE
This software upgrade only applies to the following Accessory Protocol Interface Module (APIM)
Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels:
^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC
^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD
^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD
To determine the current APIM software level, reference the Professional Technician Society (PTS)
website, enter the VIN in OASIS, click the GO
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest
for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page
8547
button and select the SYNC button.
1. Determine if communication can be established with the APIM using IDS.
a. If communication cannot be verified, proceed to Step 2.
b. If communication is present, proceed to Step 3.
2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if
communication can be established. If not, perform
an APIM power reset by disconnecting and reconnecting the vehicle battery.
a. If communication is now present, proceed to Step 3.
b. If communication still cannot be established, replace the APIM.
3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure.
NOTE
SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE
THROUGH THE SYNCMYRIDE.COM WEBSITE.
NOTE
CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS
APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID
AND PASSWORD.
a. Connect the vehicle communication module (VCM) to the data link connector (DLC).
b. Connect the VCM to the IDS tool or laptop running IDS software.
c. Turn the ignition key to the on position.
d. Launch IDS tool.
e. If required, update the VCM with the latest software.
f. Close the IDS tool.
g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle
communication is established, press the GO
button.
h. From the Vehicle Service Session screen, Select the SYNC button.
i. Press read APIM button.
j. Select software and press program APIM to update the SYNC module.
NOTE
YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER
CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP.
NOTE
DO NOT USE A TRANSFER TYPE CABLE.
NOTE
DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING.
NOTE
THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW
THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY
INCLUDED IN WINDOWS XP.
k. Program the processor in the APIM.
l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the
IDS tool or laptop running IDS software, and to the vehicle USB port.
m. Follow the on-screen instructions to program the VIP module.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest
for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page
8548
n. At the end of the configuration and programming procedure, the programming has been
completed successfully screen will be displayed.
o. Exit PTS, disconnect the VCM and disconnect the USB cable.
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
MT091403 Use SLTS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor Performed As Actual Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14D212 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Communications Control Module: > 10-2-8 > Feb > 10 > SYNC(R) System - Defaults To 'Privacy Mode'
Communications Control Module: All Technical Service Bulletins SYNC(R) System - Defaults To
'Privacy Mode'
TSB 10-2-8
02/15/10
SYNC SYSTEM DEFAULTS TO OR STAYS IN PRIVACY MODE, MULTIPLE VEHICLE LINES
FORD: 2008-2009 Taurus X 2008-2010 Focus, Fusion, Mustang, Taurus, Edge, Escape,
Expedition, Explorer Sport Trac, Explorer, F-150, F-250, F-350, F-450 2009-2010 Flex
LINCOLN: 2008-2010 MKZ 2009-2010 MKS 2008 Mark LT 2008-2010 MKX, Navigator 2010 MKT
MERCURY: 2008-2009 Sable 2008-2010 Milan, Mariner, Mountaineer
ISSUE Some customers of 2008-2010 SYNC-equipped vehicles may express concern with their
SYNC paired device defaulting, switching or staying on privacy mode. The customer may not be
able to accept the call through the SYNC system or must answer the call manually on their
personal device.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Set the Privacy mode to Off on the device and recheck Sync operation.
2. If necessary, test the device on another vehicle with the same version SYNC. If the concern is
still present, the device is the concern. Continue with
normal WSM Diagnostics.
NOTE
PRIVACY MODE MEANS THAT THE PHONE IS CONTROLLING THE AUDIO. SYNC ONLY
MAKES REQUESTS TO THE PHONE TO TRANSFER THIS RESPONSIBILITY OR AUDIO TO
SYNC. IF THE PHONE DOES NOT ACCEPT THIS REQUEST OR THERE IS A PROBLEM IN
THE COMMUNICATION TO MAKE THIS HAPPEN, YOU ARE BY DEFAULT IN PRIVACY MODE.
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For
Various Concerns
Communications Control Module: All Technical Service Bulletins SYNC(R) System - Software
Update For Various Concerns
TSB 09-26-8
01/04/10
SYNC SOFTWARE UPDATE - VARIOUS ISSUES
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009
Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner
This article supersedes TSB 9-22-14 to update the Service Procedure.
ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following
symptoms:
^ Universal Serial Bus (USB) port inoperative.
^ USB audio muting when using various non-Apple USB devices.
^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands.
^ Excessive background noise and/or poor voice sound quality.
^ Phone book auto download inoperative on supported devices.
^ SYNC steering wheel control (SWC) switches being inoperative intermittently.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace
processor (CIP) software levels.
^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report)
^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health
Report)
Service Pack files may be obtained at www.syncmyride.com.
Reprogram the APIM
Contains software fix updates for the following:
^ Phone book auto download inoperative.
^ USB audio muting.
^ SYNC steering wheel control (SWC) switches being inoperative.
^ Voice recognition on 2-digit entries.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For
Various Concerns > Page 8558
^ USB port inoperative with diagnostic trouble code (DTC) B1342.
^ Poor call sound quality.
This software update also contains enhancements that will improve the reliability of both Bluetooth
and USB connections to SYNC(R) from various consumer devices, and microphone enhancements
to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The
Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple
call handling and other mobile phone features. The USB enhancements improve support for media
players and the playing of file formats and podcasts.
NOTE
REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC
SOFTWARE PROGRAMMING TIPS.
1. Connect the vehicle communication module (VCM) to the data link connector (DLC).
2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software.
3. Turn the ignition key to the on position.
4. Launch IDS tool.
5. If required, update the VCM with the latest software.
6. Close the IDS tool.
7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle
communication is established, press the GO button.
8. From the Vehicle Service Session screen, Select the SYNC button.
9. Press read APIM button.
10. Select software and press program APIM to update the SYNC module.
NOTE
YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER
CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP.
NOTE
DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING.
NOTE
THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW
THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY
INCLUDED IN WINDOWS XP.
11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP).
NOTE
DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE.
a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the
IDS tool or laptop running IDS software and
to the vehicle USB port.
b. Follow the on-screen instructions to program both processors on the Sync module (VIP and
CIP).
12. At the end of the configuration and programming procedure, the programming has been
completed successfully screen will be displayed.
13. Exit PTS, disconnect the VCM and disconnect the USB cable.
OTHER APPLICABLE ARTICLES: 08-21-02
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
092608A 2008-2009 Edge, Explorer, 0.4 Hr.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For
Various Concerns > Page 8559
Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus,
Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty,
Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14D212 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions
Inoperative/DTC's Set
Communications Control Module: All Technical Service Bulletins SYNC(R) System - Functions
Inoperative/DTC's Set
TSB 09-14-3
07/27/09
SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY
DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED
FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge,
Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid,
Mariner
ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist
and Vehicle Health Report, may exhibit all or most of the following symptoms:
^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface
Module (APIM)
^ SYNC display menus/options blank
^ USB port inoperative
^ No SYNC Blue Tooth device connectivity
^ Voice/Phone/OK steering wheel controls inoperative
^ Lack of APIM communication
^ Parasitic battery draw with APIM connected
These symptoms may be triggered by a low battery state of charge, or a recent battery
disconnect/reconnect.
ACTION Follow the service procedure to correct the condition.
SERVICE PROCEDURE
This software upgrade only applies to the following Accessory Protocol Interface Module (APIM)
Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels:
^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC
^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD
^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD
To determine the current APIM software level, reference the Professional Technician Society (PTS)
website, enter the VIN in OASIS, click the GO
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions
Inoperative/DTC's Set > Page 8564
button and select the SYNC button.
1. Determine if communication can be established with the APIM using IDS.
a. If communication cannot be verified, proceed to Step 2.
b. If communication is present, proceed to Step 3.
2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if
communication can be established. If not, perform
an APIM power reset by disconnecting and reconnecting the vehicle battery.
a. If communication is now present, proceed to Step 3.
b. If communication still cannot be established, replace the APIM.
3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure.
NOTE
SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE
THROUGH THE SYNCMYRIDE.COM WEBSITE.
NOTE
CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS
APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID
AND PASSWORD.
a. Connect the vehicle communication module (VCM) to the data link connector (DLC).
b. Connect the VCM to the IDS tool or laptop running IDS software.
c. Turn the ignition key to the on position.
d. Launch IDS tool.
e. If required, update the VCM with the latest software.
f. Close the IDS tool.
g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle
communication is established, press the GO
button.
h. From the Vehicle Service Session screen, Select the SYNC button.
i. Press read APIM button.
j. Select software and press program APIM to update the SYNC module.
NOTE
YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER
CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP.
NOTE
DO NOT USE A TRANSFER TYPE CABLE.
NOTE
DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING.
NOTE
THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW
THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY
INCLUDED IN WINDOWS XP.
k. Program the processor in the APIM.
l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the
IDS tool or laptop running IDS software, and to the vehicle USB port.
m. Follow the on-screen instructions to program the VIP module.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions
Inoperative/DTC's Set > Page 8565
n. At the end of the configuration and programming procedure, the programming has been
completed successfully screen will be displayed.
o. Exit PTS, disconnect the VCM and disconnect the USB cable.
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
MT091403 Use SLTS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor Performed As Actual Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14D212 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Locations > Audio Control Module
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Locations > Audio Control Module > Page 8568
View 151-17
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module
(APIM)
Communications Control Module: Diagrams Accessory Protocol Interface Module (APIM)
C3342 (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module
(APIM) > Page 8571
C3342 (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module
(APIM) > Page 8572
Communications Control Module: Diagrams Audio Control Module
C290A
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module
(APIM) > Page 8573
C290B
C290C
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Diagrams > Page 8574
Communications Control Module: Service and Repair
AUDIO CONTROL MODULE (ACM)
Removal and Installation
NOTE:
- When installing a new navigation audio control module (ACM), remove the navigation DVD before
sending the ACM to an authorized audio system repair facility.
- It is not necessary to remove the ACM to retrieve the part number.
1. NOTE: Module configuration is only required if a new ACM is being installed.
Upload the ACM configuration information to the scan tool. Refer to Information Bus (Module
Configuration) to carry out programmable module installation (PMI). See: Powertrain
Management/Computers and Control Systems/Information Bus/Testing and
Inspection/Programming and Relearning
2. Remove the instrument panel center finish panel. 3. Remove the 4 screws and the ACM.
- Disconnect the ACM electrical connectors and the antenna lead-in cable(s).
4. To install, reverse the removal procedure.
- Download the configuration information to the ACM.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: >
09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set
Emergency Contact Module: Customer Interest SYNC(R) System - Functions Inoperative/DTC's
Set
TSB 09-14-3
07/27/09
SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY
DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED
FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge,
Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid,
Mariner
ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist
and Vehicle Health Report, may exhibit all or most of the following symptoms:
^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface
Module (APIM)
^ SYNC display menus/options blank
^ USB port inoperative
^ No SYNC Blue Tooth device connectivity
^ Voice/Phone/OK steering wheel controls inoperative
^ Lack of APIM communication
^ Parasitic battery draw with APIM connected
These symptoms may be triggered by a low battery state of charge, or a recent battery
disconnect/reconnect.
ACTION Follow the service procedure to correct the condition.
SERVICE PROCEDURE
This software upgrade only applies to the following Accessory Protocol Interface Module (APIM)
Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels:
^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC
^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD
^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD
To determine the current APIM software level, reference the Professional Technician Society (PTS)
website, enter the VIN in OASIS, click the GO
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: >
09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 8583
button and select the SYNC button.
1. Determine if communication can be established with the APIM using IDS.
a. If communication cannot be verified, proceed to Step 2.
b. If communication is present, proceed to Step 3.
2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if
communication can be established. If not, perform
an APIM power reset by disconnecting and reconnecting the vehicle battery.
a. If communication is now present, proceed to Step 3.
b. If communication still cannot be established, replace the APIM.
3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure.
NOTE
SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE
THROUGH THE SYNCMYRIDE.COM WEBSITE.
NOTE
CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS
APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID
AND PASSWORD.
a. Connect the vehicle communication module (VCM) to the data link connector (DLC).
b. Connect the VCM to the IDS tool or laptop running IDS software.
c. Turn the ignition key to the on position.
d. Launch IDS tool.
e. If required, update the VCM with the latest software.
f. Close the IDS tool.
g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle
communication is established, press the GO
button.
h. From the Vehicle Service Session screen, Select the SYNC button.
i. Press read APIM button.
j. Select software and press program APIM to update the SYNC module.
NOTE
YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER
CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP.
NOTE
DO NOT USE A TRANSFER TYPE CABLE.
NOTE
DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING.
NOTE
THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW
THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY
INCLUDED IN WINDOWS XP.
k. Program the processor in the APIM.
l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the
IDS tool or laptop running IDS software, and to the vehicle USB port.
m. Follow the on-screen instructions to program the VIP module.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: >
09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 8584
n. At the end of the configuration and programming procedure, the programming has been
completed successfully screen will be displayed.
o. Exit PTS, disconnect the VCM and disconnect the USB cable.
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
MT091403 Use SLTS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor Performed As Actual Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14D212 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: >
09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality
Emergency Contact Module: Customer Interest SYNC(R) System - Poor Cell Phone Sound Quality
TSB 09-13-5
07/13/09
SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE
RECOGNITION DIFFICULTIES WHILE DRIVING
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009
Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner
ISSUE Some customers of 2008-2009 SYNC equipped vehicles may express concern with their
call sound quality while using the SYNC microphone, complaints of excessive background noise
during a phone call, and/or issues with voice recognition accuracy while driving.
ACTION Follow the service procedure to correct the condition.
SERVICE PROCEDURE
The following service procedure involves updating the Accessory Protocol Interface Module (APIM)
software level and installing an external alternate SYNC microphone attached to the headliner.
NOTE
THIS PROCEDURE DOES NOT APPLY TO DEALER-INSTALLED SYNC SYSTEMS.
Do not perform Step 1 if vehicle is already equipped with SYNC 2.0 (911 and Vehicle Health
Report) or has been upgraded to consumer interface processor (CIP) level 9L3T-14D544-AE. To
determine the current APIM software level, Refer to the Professional Technician Society (PTS)
website, enter the VIN in OASIS, click the GO button, and select the SYNC button.
1. Reprogram the APIM to CIP software level 9L3T-14D544-AE. For additional information Refer to
other SYNC TSB's and WSM, Section 418-01.
Service Pack files may also be obtained at www.syncmyride.com.
When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to
test VR functionality while the vehicle is parked. If customer concerns are still present, this
procedure will not yield an improvement, and the service procedure should not be performed.
Instead, Refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to
assist customer.
The VR experience can be improved with user training and making improvements to the phone
book entries (longer entries make the system more robust). Ensure the customer does not try to
speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce
system effectiveness.
When diagnosing a concern related to call sound quality, expect marginal improvements for calls
described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints
where the call audio seems to drop out intermittently.
NOTE
THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO
THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO
NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING
WITH MICROPHONE INSTALLATION.
2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone
directly to the headliner and splicing in a jumper
harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be
functional.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: >
09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8589
a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone
installation and wire splicing locations. Refer to
Wiring Diagram (WD), Section 5-1 for recommended splicing methods.
b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or
functionality.
c. The microphone is directional. Make sure the microphone is always positioned so wire length is
minimized from view. When installing the
microphone adjacent to trim, place microphone as close to trim as possible to help minimize visible
wire.
2008-2009 Edge / MKX
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 1)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable up through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124-1 for
links to location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C211. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C210.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
cut wire ends heading up the A-pillar as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2009 Escape / Mariner
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: >
09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8590
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration (Figures 2 and 3). Firmly
press the microphone into place. Ensure the microphone is parallel and adjacent to overhead
console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an
overhead console. Proceed to Step 5 if not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 501-05 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner to
run microphone cable.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C214. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP41 (BU) and GD182 (BK-GY) from C214.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD1 82 (BK-GY).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
cut wire ends heading up the A-pillar as they are no longer used.
9. Connect the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2008-2009 Navigator / 2009 Expedition
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: >
09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8591
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figures 4 and 5)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or
positioned directly above A-pillar on headliner if not
equipped with an overhead console.
^ Proceed to Step 5 if not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online
WD, Section 124-1 for links to location and connector
views.
6. Identify circuits VMN07 (GY), RMN07 (VT), and DMN07 (shield - BK) from C298. Cut the three
circuits on the male side of the connector
(17C712 harness).
7. Identify circuits CBP31 (BU-OG) and GD133 (BK) from C298 (2008 Navigator only). Identify
circuits CBP41 (BU) and GD133 (BK) from C298
(2009 Expedition/Navigator only).
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP31 (BU-OG) and any black jumper harness wire to GD133 (BK)
for 2008 Navigator only. Blue jumper harness wire to CBP41 (BU) and any black jumper harness
wire to GD133 (BK) for 2009 Expedition/Navigator only.
^ Ensure original circuits remain connected in splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: >
09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8592
^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07
(VT) and DMN07 (shield - BK).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Connect the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the headliner.
2008-2009 Explorer / Explorer Sport Trac / Mountaineer
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 6)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner run
microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify and cut circuits VMNO7 (GY), RMNO7 (VT), and DMNO7 (shield) from C248. Cut the
three circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP05 (YE) and GD143 (BK-VT) from C248.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP05 (YE) and any black jumper harness wire to GD143 (BK-VT).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07
(VT) and DMN07 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
cut wire ends heading up the A-pillar as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2009 F-150
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: >
09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8593
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 7)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp.
2. Lower the overhead console or front lamp. Refer to WSM, Section 417-02 for additional
information.
3. Route microphone cable through existing hole in the headliner, and temporarily tuck excess wire
into headliner to the rear of the console or lamp.
4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or
front lamp trim directly behind microphone as
shown.
5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD,
Section 124-1 for links to location and connector
views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C314. Cut the three
circuits on the female side of the connector
(14358 harness).
7. Identify circuits CBP41 (BU) from C315 and GD133 (BK) from C314.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the headliner.
2009 F-Super Duty
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: >
09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8594
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 8)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
c. This repair is not recommended for vehicles not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield - BK) from C264. Cut the
three circuits on the female side of the connector
(17K745 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C264.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield - BK).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Connect the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2009 Flex
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: >
09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8595
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 9)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C925. Cut the three
circuits on the female side of the connector (14334 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C925.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2008-2009 Focus
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: >
09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8596
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration (Figure 10). Firmly press
the microphone into place. Ensure the microphone is parallel and adjacent to the dome lamp trim.
2. Lower the dome lamp assembly. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable up through existing hole in the headliner, and over to the passenger
side A-pillar. It may be necessary to slightly drop
headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install dome lamp assembly; ensure microphone cable enters the dome lamp trim directly behind
microphone as shown.
5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector
views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C934. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CPL60 (BN-YE) and GD161 (BK-YE) from C934.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CPL60 (BN-YE) and any black jumper harness wire to GD161
(BK-YE).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2008-2009 Fusion / Milan / MKZ
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: >
09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8597
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 11)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C913. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP02 (GN) and GD139 (BK-YE) from C913.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP02 (GN) and any black jumper harness wire to GD139 (BK-YE).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2008-2009 Taurus / Sable / Taurus X
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 12)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner to
run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: >
09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8598
5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMN02 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C925. Cut the
three circuits on the female side of the connector
(17K745 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C925.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to
RMN02 (VT-BN) and DMN07 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2009 MKS
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 13)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and out the front of the headliner
above the rear view mirror.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124-1 for
links to location and connector views.
6. Identify circuits VMNO2 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C911. Pull back
the black harness sleeve and cut the three
circuits near C91 1 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2
access cover and cut circuits under trim cover. Refer to WSM, Section 417-01 for additional
information.
7. Identify circuits CBP41 (BU) and GD133 (BK) from C911.
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Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: >
09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 8599
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to
RMN02 (VT-BN) and DMN07 (shield).
^ Only splice into the wires heading away from the connector. The wires heading into the connector
(mirror) are no longer used.
^ Ensure the wiring is neatly routed from the splice locations into the headliner, following the
existing wire harness routing from mirror to headliner.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
OTHER APPLICABLE ARTICLES: 08-21-2
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
MT091305 Claim Diagnosis And Labor Actual
Performed As Actual Time. Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
17700 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set
Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - Functions
Inoperative/DTC's Set
TSB 09-14-3
07/27/09
SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY
DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED
FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge,
Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid,
Mariner
ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist
and Vehicle Health Report, may exhibit all or most of the following symptoms:
^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface
Module (APIM)
^ SYNC display menus/options blank
^ USB port inoperative
^ No SYNC Blue Tooth device connectivity
^ Voice/Phone/OK steering wheel controls inoperative
^ Lack of APIM communication
^ Parasitic battery draw with APIM connected
These symptoms may be triggered by a low battery state of charge, or a recent battery
disconnect/reconnect.
ACTION Follow the service procedure to correct the condition.
SERVICE PROCEDURE
This software upgrade only applies to the following Accessory Protocol Interface Module (APIM)
Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels:
^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC
^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD
^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD
To determine the current APIM software level, reference the Professional Technician Society (PTS)
website, enter the VIN in OASIS, click the GO
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Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set >
Page 8605
button and select the SYNC button.
1. Determine if communication can be established with the APIM using IDS.
a. If communication cannot be verified, proceed to Step 2.
b. If communication is present, proceed to Step 3.
2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if
communication can be established. If not, perform
an APIM power reset by disconnecting and reconnecting the vehicle battery.
a. If communication is now present, proceed to Step 3.
b. If communication still cannot be established, replace the APIM.
3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure.
NOTE
SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE
THROUGH THE SYNCMYRIDE.COM WEBSITE.
NOTE
CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS
APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID
AND PASSWORD.
a. Connect the vehicle communication module (VCM) to the data link connector (DLC).
b. Connect the VCM to the IDS tool or laptop running IDS software.
c. Turn the ignition key to the on position.
d. Launch IDS tool.
e. If required, update the VCM with the latest software.
f. Close the IDS tool.
g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle
communication is established, press the GO
button.
h. From the Vehicle Service Session screen, Select the SYNC button.
i. Press read APIM button.
j. Select software and press program APIM to update the SYNC module.
NOTE
YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER
CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP.
NOTE
DO NOT USE A TRANSFER TYPE CABLE.
NOTE
DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING.
NOTE
THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW
THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY
INCLUDED IN WINDOWS XP.
k. Program the processor in the APIM.
l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the
IDS tool or laptop running IDS software, and to the vehicle USB port.
m. Follow the on-screen instructions to program the VIP module.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set >
Page 8606
n. At the end of the configuration and programming procedure, the programming has been
completed successfully screen will be displayed.
o. Exit PTS, disconnect the VCM and disconnect the USB cable.
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
MT091403 Use SLTS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor Performed As Actual Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
14D212 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality
Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - Poor Cell Phone
Sound Quality
TSB 09-13-5
07/13/09
SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE
RECOGNITION DIFFICULTIES WHILE DRIVING
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009
Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner
ISSUE Some customers of 2008-2009 SYNC equipped vehicles may express concern with their
call sound quality while using the SYNC microphone, complaints of excessive background noise
during a phone call, and/or issues with voice recognition accuracy while driving.
ACTION Follow the service procedure to correct the condition.
SERVICE PROCEDURE
The following service procedure involves updating the Accessory Protocol Interface Module (APIM)
software level and installing an external alternate SYNC microphone attached to the headliner.
NOTE
THIS PROCEDURE DOES NOT APPLY TO DEALER-INSTALLED SYNC SYSTEMS.
Do not perform Step 1 if vehicle is already equipped with SYNC 2.0 (911 and Vehicle Health
Report) or has been upgraded to consumer interface processor (CIP) level 9L3T-14D544-AE. To
determine the current APIM software level, Refer to the Professional Technician Society (PTS)
website, enter the VIN in OASIS, click the GO button, and select the SYNC button.
1. Reprogram the APIM to CIP software level 9L3T-14D544-AE. For additional information Refer to
other SYNC TSB's and WSM, Section 418-01.
Service Pack files may also be obtained at www.syncmyride.com.
When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to
test VR functionality while the vehicle is parked. If customer concerns are still present, this
procedure will not yield an improvement, and the service procedure should not be performed.
Instead, Refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to
assist customer.
The VR experience can be improved with user training and making improvements to the phone
book entries (longer entries make the system more robust). Ensure the customer does not try to
speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce
system effectiveness.
When diagnosing a concern related to call sound quality, expect marginal improvements for calls
described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints
where the call audio seems to drop out intermittently.
NOTE
THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO
THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO
NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING
WITH MICROPHONE INSTALLATION.
2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone
directly to the headliner and splicing in a jumper
harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be
functional.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
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Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page
8611
a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone
installation and wire splicing locations. Refer to
Wiring Diagram (WD), Section 5-1 for recommended splicing methods.
b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or
functionality.
c. The microphone is directional. Make sure the microphone is always positioned so wire length is
minimized from view. When installing the
microphone adjacent to trim, place microphone as close to trim as possible to help minimize visible
wire.
2008-2009 Edge / MKX
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 1)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable up through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124-1 for
links to location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C211. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C210.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
cut wire ends heading up the A-pillar as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2009 Escape / Mariner
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page
8612
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration (Figures 2 and 3). Firmly
press the microphone into place. Ensure the microphone is parallel and adjacent to overhead
console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an
overhead console. Proceed to Step 5 if not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 501-05 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner to
run microphone cable.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C214. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP41 (BU) and GD182 (BK-GY) from C214.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD1 82 (BK-GY).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
cut wire ends heading up the A-pillar as they are no longer used.
9. Connect the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2008-2009 Navigator / 2009 Expedition
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page
8613
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figures 4 and 5)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or
positioned directly above A-pillar on headliner if not
equipped with an overhead console.
^ Proceed to Step 5 if not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online
WD, Section 124-1 for links to location and connector
views.
6. Identify circuits VMN07 (GY), RMN07 (VT), and DMN07 (shield - BK) from C298. Cut the three
circuits on the male side of the connector
(17C712 harness).
7. Identify circuits CBP31 (BU-OG) and GD133 (BK) from C298 (2008 Navigator only). Identify
circuits CBP41 (BU) and GD133 (BK) from C298
(2009 Expedition/Navigator only).
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP31 (BU-OG) and any black jumper harness wire to GD133 (BK)
for 2008 Navigator only. Blue jumper harness wire to CBP41 (BU) and any black jumper harness
wire to GD133 (BK) for 2009 Expedition/Navigator only.
^ Ensure original circuits remain connected in splice.
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Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page
8614
^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07
(VT) and DMN07 (shield - BK).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Connect the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the headliner.
2008-2009 Explorer / Explorer Sport Trac / Mountaineer
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 6)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner run
microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify and cut circuits VMNO7 (GY), RMNO7 (VT), and DMNO7 (shield) from C248. Cut the
three circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP05 (YE) and GD143 (BK-VT) from C248.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP05 (YE) and any black jumper harness wire to GD143 (BK-VT).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07
(VT) and DMN07 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
cut wire ends heading up the A-pillar as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2009 F-150
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Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page
8615
1. Remove the protective backing from the adhesive on the microphone and attach the
microphone. (Figure 7)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp.
2. Lower the overhead console or front lamp. Refer to WSM, Section 417-02 for additional
information.
3. Route microphone cable through existing hole in the headliner, and temporarily tuck excess wire
into headliner to the rear of the console or lamp.
4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or
front lamp trim directly behind microphone as
shown.
5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD,
Section 124-1 for links to location and connector
views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C314. Cut the three
circuits on the female side of the connector
(14358 harness).
7. Identify circuits CBP41 (BU) from C315 and GD133 (BK) from C314.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the headliner.
2009 F-Super Duty
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page
8616
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 8)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
c. This repair is not recommended for vehicles not equipped with an overhead console.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield - BK) from C264. Cut the
three circuits on the female side of the connector
(17K745 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C264.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield - BK).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Connect the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2009 Flex
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page
8617
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 9)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C925. Cut the three
circuits on the female side of the connector (14334 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C925.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2008-2009 Focus
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page
8618
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration (Figure 10). Firmly press
the microphone into place. Ensure the microphone is parallel and adjacent to the dome lamp trim.
2. Lower the dome lamp assembly. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable up through existing hole in the headliner, and over to the passenger
side A-pillar. It may be necessary to slightly drop
headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install dome lamp assembly; ensure microphone cable enters the dome lamp trim directly behind
microphone as shown.
5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector
views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C934. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CPL60 (BN-YE) and GD161 (BK-YE) from C934.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CPL60 (BN-YE) and any black jumper harness wire to GD161
(BK-YE).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable over the front of the headliner.
2008-2009 Fusion / Milan / MKZ
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page
8619
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 11)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the passenger side
A-pillar. It may be necessary to slightly drop headliner
to run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C913. Cut the three
circuits on the female side of the connector
(14334 harness).
7. Identify circuits CBP02 (GN) and GD139 (BK-YE) from C913.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP02 (GN) and any black jumper harness wire to GD139 (BK-YE).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to
RMM13 (BU) and DMM13 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2008-2009 Taurus / Sable / Taurus X
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 12)
^ Firmly press the microphone into place.
^ Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and over to the driver side
A-pillar. It may be necessary to slightly drop headliner to
run microphone cable. Refer to WSM, Section 501-05 for additional information.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page
8620
5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124-1 for links to
location and connector views.
6. Identify circuits VMN02 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C925. Cut the
three circuits on the female side of the connector
(17K745 harness).
7. Identify circuits CBP41 (BU) and GD133 (BK) from C925.
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to
RMN02 (VT-BN) and DMN07 (shield).
^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the
other cut wire ends as they are no longer used.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
2009 MKS
1. Remove the protective backing from the adhesive on the microphone and attach the microphone
as shown in the illustration. (Figure 13)
a. Firmly press the microphone into place.
b. Ensure the microphone is parallel and adjacent to overhead console trim.
2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information.
3. Route microphone cable through existing hole in the headliner, and out the front of the headliner
above the rear view mirror.
4. Install overhead console; ensure microphone cable enters the overhead console trim directly
behind microphone as shown.
5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124-1 for
links to location and connector views.
6. Identify circuits VMNO2 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C911. Pull back
the black harness sleeve and cut the three
circuits near C91 1 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2
access cover and cut circuits under trim cover. Refer to WSM, Section 417-01 for additional
information.
7. Identify circuits CBP41 (BU) and GD133 (BK) from C911.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page
8621
8. Splice the five jumper harness wires into the following circuits:
^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK).
^ Ensure original circuits remain connected in splice.
^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to
RMN02 (VT-BN) and DMN07 (shield).
^ Only splice into the wires heading away from the connector. The wires heading into the connector
(mirror) are no longer used.
^ Ensure the wiring is neatly routed from the splice locations into the headliner, following the
existing wire harness routing from mirror to headliner.
9. Attach the microphone connector to the jumper harness connector.
10. Bundle and tuck the remainder of the microphone cable above the front of the headliner.
OTHER APPLICABLE ARTICLES: 08-21-2
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
MT091305 Claim Diagnosis And Labor Actual
Performed As Actual Time. Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
17700 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade
Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - 911 Assist VHR
Software Upgrade
TSB 09-11-8
06/15/09
SYNC WITH 911 ASSIST AND VEHICLE HEALTH REPORT (VHR) DEALER UPGRADE
SOFTWARE
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009
Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner
This article supersedes TSB 9-5-4 to update the Service Procedure and add a production fix date.
ISSUE Some customers with 2008 or 2009 vehicles equipped with SYNC may request the 911
assist and vehicle health report (VHR) service upgrade installation. This software upgrade is not a
warrantable repair. Software is available only through professional technician society (PTS)
website, and not available through the syncmyride.com website.
ACTION Follow the Service Procedure steps to upgrade the SYNC software.
SERVICE PROCEDURE
This software upgrade applies only to the following vehicle model years and build dates:
^ 2008-2009 Focus built before 1/20/2009
^ 2008-2009 Explorer, Explorer Sport Trac, Mountaineer built before 1/12/2009
^ 2008-2009 Edge, MKX, and 2009 Flex, Escape, Mariner built before 12/4/2008
^ 2008-2009 Taurus, Taurus X, Sable, and 2009 F-Super Duty, MKS, F-150 built before 12/1/2008
^ 2008-2009 Fusion, Milan, MKZ
Vehicles built on or after these dates are already equipped with the 911 Assist/Vehicle Health
Report features and do not require updating.
To determine if the vehicles are within these build ranges or have already been upgraded to SYNC
911 Assist/VHR, access the Professional Technician Society (PTS) website, run OASIS by
pressing the Read VIN and DTC's button, and click on the SYNC tab. If the description box
indicates 911 and Vehicle Health Report, vehicle has been upgraded.
The 911 assist with VHR upgrade automatically reprograms the accessory protocol interface
module (APIM), instrument cluster (IC), and restraints control module (RCM).
The VHR applies only to United States (US) vehicles, 911 assist is for US and Canadian vehicles
operated within the US and Canada.
Performing this upgrade may result in some untested devices losing certain functionality, such as
bluetooth connection and phonebook download. Before continuing with this upgrade, make sure
the customer's device is listed on the compatibility matrix. It is strongly recommended to pair the
device to another vehicle currently equipped with 911 Assist/Vehicle Health Report to ensure
proper functionality before continuing.
Configuration and programming requires the use of IDS and a special PTS application. Installer
must have access to PTS and have a valid PTS user ID and password. Ensure the IDS is at the
latest software version.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade >
Page 8626
For additional programming tips, dealer network setting requirements, and possible error states
related to 911 Assist and VHR upgrades, reference the latest information on the Professional
Technician Society (PTS) website.
1. When updating 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator
vehicles, it is necessary to manually record and
reenter the Oil Life % Value as displayed on the message center. Record the current oil life before
updating 911 Assist/VHR, and reenter using the message center once programming is complete.
2. Connect the vehicle communication module (VCM) to the data link connector (DLC).
3. Connect the VCM to the IDS tool or laptop running IDS software.
4. Turn the ignition key to the on position.
5. Launch IDS tool but do not start a new session.
6. If required, update the VCM with the latest IDS release 59.9 and higher.
7. Close the IDS tool.
8. From the P15 website, run OASIS by pressing the read VIN and DTC's button. After vehicle
communication is established, press the go button.
9. From the Vehicle Service Session screen, select the Upgrade/Mods tab.
10. Once correct vehicle is chosen, select SYNC upgrade with 911 Assist/VHR.
11. Follow the on-screen instructions to program the APIM, IC, and RCM.
NOTE
TO COMPLETE THE UPGRADE PROCESS PERFORM THE FOLLOWING STEPS TO CONFIRM
THE VEHICLE HAS BEEN CORRECTLY CONFIGURED TO HAVE THESE FEATURES. FAILING
TO COMPLETE THE STEPS BELOW MAY RESULT IN 911 ASSIST/VHR NOT DISPLAYING ON
THE SYNC MENU.
12. Set ignition to off.
13. Open and close driver side door.
14. Set ignition to on.
15. Follow applicable instructions (see below) to ensure 911 Assist/VHR appear on Sync menu.
16. Close all Internet Explorer browser windows.
17. Clear all DTC's on all modules.
18. Reenter the Oil Life % Value for 2008-2009 Explorer, Mountaineer, Explorer Sport Trac,
Expedition, or Navigator vehicles.
Navigation Radio Instructions
911 Assist/VHR feature confirmation.
1. Press phone button on the Navigation LCD to enter phone menu.
2. Press cancel when pop-up menu appears on Navigation LCD display.
3. Press settings soft key on Navigation LCD display.
4. Press advanced soft key on Navigation LCD display.
5. Verify 911 Assist/VHR is in menu in Navigation LCD display.
Non Navigation Radio Instructions
911 Assist/VHR feature confirmation.
1. Press phone button on steering wheel.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade >
Page 8627
2. Press left arrow on steering wheel until return is displayed on radio screen, then press ok.
3. Press left arrow on steering wheel until return is displayed on radio screen, then press ok.
4. Press left arrow until 911 Assist/VHR is displayed.
Once 911 Assist/VHR installation is complete, the customer will need to reload their phone book if
that application is desired.
NOTE
IF SERVICE IS REQUIRED ON 2008 OR 2009 EARLY BUILT VEHICLES UPGRADED TO 911
ASSIST/VHR, REFERENCE THE APPLICABLE 2009 WORKSHOP MANUAL AND FOLLOW THE
V2 DIAGNOSTIC PROCEDURES.
WARRANTY STATUS: Information Only - Not Warrantable
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade
Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - 911 Assist VHR
Software Upgrade
TSB 09-11-8
06/15/09
SYNC WITH 911 ASSIST AND VEHICLE HEALTH REPORT (VHR) DEALER UPGRADE
SOFTWARE
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009
Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner
This article supersedes TSB 9-5-4 to update the Service Procedure and add a production fix date.
ISSUE Some customers with 2008 or 2009 vehicles equipped with SYNC may request the 911
assist and vehicle health report (VHR) service upgrade installation. This software upgrade is not a
warrantable repair. Software is available only through professional technician society (PTS)
website, and not available through the syncmyride.com website.
ACTION Follow the Service Procedure steps to upgrade the SYNC software.
SERVICE PROCEDURE
This software upgrade applies only to the following vehicle model years and build dates:
^ 2008-2009 Focus built before 1/20/2009
^ 2008-2009 Explorer, Explorer Sport Trac, Mountaineer built before 1/12/2009
^ 2008-2009 Edge, MKX, and 2009 Flex, Escape, Mariner built before 12/4/2008
^ 2008-2009 Taurus, Taurus X, Sable, and 2009 F-Super Duty, MKS, F-150 built before 12/1/2008
^ 2008-2009 Fusion, Milan, MKZ
Vehicles built on or after these dates are already equipped with the 911 Assist/Vehicle Health
Report features and do not require updating.
To determine if the vehicles are within these build ranges or have already been upgraded to SYNC
911 Assist/VHR, access the Professional Technician Society (PTS) website, run OASIS by
pressing the Read VIN and DTC's button, and click on the SYNC tab. If the description box
indicates 911 and Vehicle Health Report, vehicle has been upgraded.
The 911 assist with VHR upgrade automatically reprograms the accessory protocol interface
module (APIM), instrument cluster (IC), and restraints control module (RCM).
The VHR applies only to United States (US) vehicles, 911 assist is for US and Canadian vehicles
operated within the US and Canada.
Performing this upgrade may result in some untested devices losing certain functionality, such as
bluetooth connection and phonebook download. Before continuing with this upgrade, make sure
the customer's device is listed on the compatibility matrix. It is strongly recommended to pair the
device to another vehicle currently equipped with 911 Assist/Vehicle Health Report to ensure
proper functionality before continuing.
Configuration and programming requires the use of IDS and a special PTS application. Installer
must have access to PTS and have a valid PTS user ID and password. Ensure the IDS is at the
latest software version.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade >
Page 8633
For additional programming tips, dealer network setting requirements, and possible error states
related to 911 Assist and VHR upgrades, reference the latest information on the Professional
Technician Society (PTS) website.
1. When updating 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator
vehicles, it is necessary to manually record and
reenter the Oil Life % Value as displayed on the message center. Record the current oil life before
updating 911 Assist/VHR, and reenter using the message center once programming is complete.
2. Connect the vehicle communication module (VCM) to the data link connector (DLC).
3. Connect the VCM to the IDS tool or laptop running IDS software.
4. Turn the ignition key to the on position.
5. Launch IDS tool but do not start a new session.
6. If required, update the VCM with the latest IDS release 59.9 and higher.
7. Close the IDS tool.
8. From the P15 website, run OASIS by pressing the read VIN and DTC's button. After vehicle
communication is established, press the go button.
9. From the Vehicle Service Session screen, select the Upgrade/Mods tab.
10. Once correct vehicle is chosen, select SYNC upgrade with 911 Assist/VHR.
11. Follow the on-screen instructions to program the APIM, IC, and RCM.
NOTE
TO COMPLETE THE UPGRADE PROCESS PERFORM THE FOLLOWING STEPS TO CONFIRM
THE VEHICLE HAS BEEN CORRECTLY CONFIGURED TO HAVE THESE FEATURES. FAILING
TO COMPLETE THE STEPS BELOW MAY RESULT IN 911 ASSIST/VHR NOT DISPLAYING ON
THE SYNC MENU.
12. Set ignition to off.
13. Open and close driver side door.
14. Set ignition to on.
15. Follow applicable instructions (see below) to ensure 911 Assist/VHR appear on Sync menu.
16. Close all Internet Explorer browser windows.
17. Clear all DTC's on all modules.
18. Reenter the Oil Life % Value for 2008-2009 Explorer, Mountaineer, Explorer Sport Trac,
Expedition, or Navigator vehicles.
Navigation Radio Instructions
911 Assist/VHR feature confirmation.
1. Press phone button on the Navigation LCD to enter phone menu.
2. Press cancel when pop-up menu appears on Navigation LCD display.
3. Press settings soft key on Navigation LCD display.
4. Press advanced soft key on Navigation LCD display.
5. Verify 911 Assist/VHR is in menu in Navigation LCD display.
Non Navigation Radio Instructions
911 Assist/VHR feature confirmation.
1. Press phone button on steering wheel.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade >
Page 8634
2. Press left arrow on steering wheel until return is displayed on radio screen, then press ok.
3. Press left arrow on steering wheel until return is displayed on radio screen, then press ok.
4. Press left arrow until 911 Assist/VHR is displayed.
Once 911 Assist/VHR installation is complete, the customer will need to reload their phone book if
that application is desired.
NOTE
IF SERVICE IS REQUIRED ON 2008 OR 2009 EARLY BUILT VEHICLES UPGRADED TO 911
ASSIST/VHR, REFERENCE THE APPLICABLE 2009 WORKSHOP MANUAL AND FOLLOW THE
V2 DIAGNOSTIC PROCEDURES.
WARRANTY STATUS: Information Only - Not Warrantable
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Entertainment System Control Module > Component Information > Technical Service Bulletins > Customer
Interest for Entertainment System Control Module: > 10-9-7 > May > 10 > Audio System - Unexpected CD Shuffle With Key
Off
Entertainment System Control Module: Customer Interest Audio System - Unexpected CD Shuffle
With Key Off
TSB 10-9-7
05/24/10
UNEXPECTED COMPACT DISC SHUFFLE OR CYCLING DURING NORMAL RADIO
OPERATION OR WITH THE KEY OFF - NON-NAVIGATION RADIOS ONLY
FORD: 2008-2010 Expedition, Explorer Sport Trac, Explorer
MERCURY: 2008-2010 Mountaineer
ISSUE Some 2008-2010 Expedition, Explorer, Explorer Sport Trac and Mountaineer vehicles
equipped with a non-navigation CD-6 Audio Control Module (ACM) may experience an unexpected
Compact Disc (CD) shuffle or cycling during start up, during normal ACM operation, or shutting off
the vehicle.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
This service procedure affects non-navigation radios only. If you attempt to run module
reprogramming on the 2008-2010 ACM and the service tool does not recognize the part numbers
of the ACM currently installed, this procedure does not apply.
Reprogram the ACM to the latest calibration using IDS release 66.05A and higher. This new
calibration is not included in the VCM 2010. Version A 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
100907A 2008-2010 Expedition, 0.3 Hr.
Explorer, Mountaineer, And Explorer Sport Trac: Reprogram The Audio Control Module (Do Not
Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Entertainment System Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Entertainment System Control Module: > 10-9-7 > May > 10 > Audio System - Unexpected CD Shuffle
With Key Off
Entertainment System Control Module: All Technical Service Bulletins Audio System - Unexpected
CD Shuffle With Key Off
TSB 10-9-7
05/24/10
UNEXPECTED COMPACT DISC SHUFFLE OR CYCLING DURING NORMAL RADIO
OPERATION OR WITH THE KEY OFF - NON-NAVIGATION RADIOS ONLY
FORD: 2008-2010 Expedition, Explorer Sport Trac, Explorer
MERCURY: 2008-2010 Mountaineer
ISSUE Some 2008-2010 Expedition, Explorer, Explorer Sport Trac and Mountaineer vehicles
equipped with a non-navigation CD-6 Audio Control Module (ACM) may experience an unexpected
Compact Disc (CD) shuffle or cycling during start up, during normal ACM operation, or shutting off
the vehicle.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
This service procedure affects non-navigation radios only. If you attempt to run module
reprogramming on the 2008-2010 ACM and the service tool does not recognize the part numbers
of the ACM currently installed, this procedure does not apply.
Reprogram the ACM to the latest calibration using IDS release 66.05A and higher. This new
calibration is not included in the VCM 2010. Version A 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
100907A 2008-2010 Expedition, 0.3 Hr.
Explorer, Mountaineer, And Explorer Sport Trac: Reprogram The Audio Control Module (Do Not
Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer
Interest for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various
Concerns
Global Positioning System Module: Customer Interest SYNC(R) System - Software Update For
Various Concerns
TSB 09-26-8
01/04/10
SYNC SOFTWARE UPDATE - VARIOUS ISSUES
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009
Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner
This article supersedes TSB 9-22-14 to update the Service Procedure.
ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following
symptoms:
^ Universal Serial Bus (USB) port inoperative.
^ USB audio muting when using various non-Apple USB devices.
^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands.
^ Excessive background noise and/or poor voice sound quality.
^ Phone book auto download inoperative on supported devices.
^ SYNC steering wheel control (SWC) switches being inoperative intermittently.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace
processor (CIP) software levels.
^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report)
^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health
Report)
Service Pack files may be obtained at www.syncmyride.com.
Reprogram the APIM
Contains software fix updates for the following:
^ Phone book auto download inoperative.
^ USB audio muting.
^ SYNC steering wheel control (SWC) switches being inoperative.
^ Voice recognition on 2-digit entries.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer
Interest for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various
Concerns > Page 8656
^ USB port inoperative with diagnostic trouble code (DTC) B1342.
^ Poor call sound quality.
This software update also contains enhancements that will improve the reliability of both Bluetooth
and USB connections to SYNC(R) from various consumer devices, and microphone enhancements
to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The
Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple
call handling and other mobile phone features. The USB enhancements improve support for media
players and the playing of file formats and podcasts.
NOTE
REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC
SOFTWARE PROGRAMMING TIPS.
1. Connect the vehicle communication module (VCM) to the data link connector (DLC).
2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software.
3. Turn the ignition key to the on position.
4. Launch IDS tool.
5. If required, update the VCM with the latest software.
6. Close the IDS tool.
7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle
communication is established, press the GO button.
8. From the Vehicle Service Session screen, Select the SYNC button.
9. Press read APIM button.
10. Select software and press program APIM to update the SYNC module.
NOTE
YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER
CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP.
NOTE
DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING.
NOTE
THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW
THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY
INCLUDED IN WINDOWS XP.
11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP).
NOTE
DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE.
a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the
IDS tool or laptop running IDS software and
to the vehicle USB port.
b. Follow the on-screen instructions to program both processors on the Sync module (VIP and
CIP).
12. At the end of the configuration and programming procedure, the programming has been
completed successfully screen will be displayed.
13. Exit PTS, disconnect the VCM and disconnect the USB cable.
OTHER APPLICABLE ARTICLES: 08-21-02
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
092608A 2008-2009 Edge, Explorer, 0.4 Hr.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer
Interest for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various
Concerns > Page 8657
Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus,
Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty,
Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14D212 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For
Various Concerns
Global Positioning System Module: All Technical Service Bulletins SYNC(R) System - Software
Update For Various Concerns
TSB 09-26-8
01/04/10
SYNC SOFTWARE UPDATE - VARIOUS ISSUES
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009
Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner
This article supersedes TSB 9-22-14 to update the Service Procedure.
ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following
symptoms:
^ Universal Serial Bus (USB) port inoperative.
^ USB audio muting when using various non-Apple USB devices.
^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands.
^ Excessive background noise and/or poor voice sound quality.
^ Phone book auto download inoperative on supported devices.
^ SYNC steering wheel control (SWC) switches being inoperative intermittently.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace
processor (CIP) software levels.
^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report)
^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health
Report)
Service Pack files may be obtained at www.syncmyride.com.
Reprogram the APIM
Contains software fix updates for the following:
^ Phone book auto download inoperative.
^ USB audio muting.
^ SYNC steering wheel control (SWC) switches being inoperative.
^ Voice recognition on 2-digit entries.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For
Various Concerns > Page 8663
^ USB port inoperative with diagnostic trouble code (DTC) B1342.
^ Poor call sound quality.
This software update also contains enhancements that will improve the reliability of both Bluetooth
and USB connections to SYNC(R) from various consumer devices, and microphone enhancements
to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The
Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple
call handling and other mobile phone features. The USB enhancements improve support for media
players and the playing of file formats and podcasts.
NOTE
REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC
SOFTWARE PROGRAMMING TIPS.
1. Connect the vehicle communication module (VCM) to the data link connector (DLC).
2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software.
3. Turn the ignition key to the on position.
4. Launch IDS tool.
5. If required, update the VCM with the latest software.
6. Close the IDS tool.
7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle
communication is established, press the GO button.
8. From the Vehicle Service Session screen, Select the SYNC button.
9. Press read APIM button.
10. Select software and press program APIM to update the SYNC module.
NOTE
YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER
CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP.
NOTE
DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING.
NOTE
THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW
THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY
INCLUDED IN WINDOWS XP.
11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP).
NOTE
DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE.
a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the
IDS tool or laptop running IDS software and
to the vehicle USB port.
b. Follow the on-screen instructions to program both processors on the Sync module (VIP and
CIP).
12. At the end of the configuration and programming procedure, the programming has been
completed successfully screen will be displayed.
13. Exit PTS, disconnect the VCM and disconnect the USB cable.
OTHER APPLICABLE ARTICLES: 08-21-02
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
092608A 2008-2009 Edge, Explorer, 0.4 Hr.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For
Various Concerns > Page 8664
Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus,
Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty,
Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14D212 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation
Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns
Navigation Module: Customer Interest SYNC(R) System - Software Update For Various Concerns
TSB 09-26-8
01/04/10
SYNC SOFTWARE UPDATE - VARIOUS ISSUES
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009
Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner
This article supersedes TSB 9-22-14 to update the Service Procedure.
ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following
symptoms:
^ Universal Serial Bus (USB) port inoperative.
^ USB audio muting when using various non-Apple USB devices.
^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands.
^ Excessive background noise and/or poor voice sound quality.
^ Phone book auto download inoperative on supported devices.
^ SYNC steering wheel control (SWC) switches being inoperative intermittently.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace
processor (CIP) software levels.
^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report)
^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health
Report)
Service Pack files may be obtained at www.syncmyride.com.
Reprogram the APIM
Contains software fix updates for the following:
^ Phone book auto download inoperative.
^ USB audio muting.
^ SYNC steering wheel control (SWC) switches being inoperative.
^ Voice recognition on 2-digit entries.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation
Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 8673
^ USB port inoperative with diagnostic trouble code (DTC) B1342.
^ Poor call sound quality.
This software update also contains enhancements that will improve the reliability of both Bluetooth
and USB connections to SYNC(R) from various consumer devices, and microphone enhancements
to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The
Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple
call handling and other mobile phone features. The USB enhancements improve support for media
players and the playing of file formats and podcasts.
NOTE
REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC
SOFTWARE PROGRAMMING TIPS.
1. Connect the vehicle communication module (VCM) to the data link connector (DLC).
2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software.
3. Turn the ignition key to the on position.
4. Launch IDS tool.
5. If required, update the VCM with the latest software.
6. Close the IDS tool.
7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle
communication is established, press the GO button.
8. From the Vehicle Service Session screen, Select the SYNC button.
9. Press read APIM button.
10. Select software and press program APIM to update the SYNC module.
NOTE
YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER
CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP.
NOTE
DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING.
NOTE
THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW
THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY
INCLUDED IN WINDOWS XP.
11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP).
NOTE
DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE.
a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the
IDS tool or laptop running IDS software and
to the vehicle USB port.
b. Follow the on-screen instructions to program both processors on the Sync module (VIP and
CIP).
12. At the end of the configuration and programming procedure, the programming has been
completed successfully screen will be displayed.
13. Exit PTS, disconnect the VCM and disconnect the USB cable.
OTHER APPLICABLE ARTICLES: 08-21-02
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
092608A 2008-2009 Edge, Explorer, 0.4 Hr.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation
Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 8674
Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus,
Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty,
Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14D212 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns
Navigation Module: All Technical Service Bulletins SYNC(R) System - Software Update For
Various Concerns
TSB 09-26-8
01/04/10
SYNC SOFTWARE UPDATE - VARIOUS ISSUES
FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009
Escape, Expedition, F-150, F-Super Duty, Flex
LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator
MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner
This article supersedes TSB 9-22-14 to update the Service Procedure.
ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following
symptoms:
^ Universal Serial Bus (USB) port inoperative.
^ USB audio muting when using various non-Apple USB devices.
^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands.
^ Excessive background noise and/or poor voice sound quality.
^ Phone book auto download inoperative on supported devices.
^ SYNC steering wheel control (SWC) switches being inoperative intermittently.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace
processor (CIP) software levels.
^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report)
^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health
Report)
Service Pack files may be obtained at www.syncmyride.com.
Reprogram the APIM
Contains software fix updates for the following:
^ Phone book auto download inoperative.
^ USB audio muting.
^ SYNC steering wheel control (SWC) switches being inoperative.
^ Voice recognition on 2-digit entries.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 8680
^ USB port inoperative with diagnostic trouble code (DTC) B1342.
^ Poor call sound quality.
This software update also contains enhancements that will improve the reliability of both Bluetooth
and USB connections to SYNC(R) from various consumer devices, and microphone enhancements
to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The
Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple
call handling and other mobile phone features. The USB enhancements improve support for media
players and the playing of file formats and podcasts.
NOTE
REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC
SOFTWARE PROGRAMMING TIPS.
1. Connect the vehicle communication module (VCM) to the data link connector (DLC).
2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software.
3. Turn the ignition key to the on position.
4. Launch IDS tool.
5. If required, update the VCM with the latest software.
6. Close the IDS tool.
7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle
communication is established, press the GO button.
8. From the Vehicle Service Session screen, Select the SYNC button.
9. Press read APIM button.
10. Select software and press program APIM to update the SYNC module.
NOTE
YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER
CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP.
NOTE
DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING.
NOTE
THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW
THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY
INCLUDED IN WINDOWS XP.
11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP).
NOTE
DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE.
a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the
IDS tool or laptop running IDS software and
to the vehicle USB port.
b. Follow the on-screen instructions to program both processors on the Sync module (VIP and
CIP).
12. At the end of the configuration and programming procedure, the programming has been
completed successfully screen will be displayed.
13. Exit PTS, disconnect the VCM and disconnect the USB cable.
OTHER APPLICABLE ARTICLES: 08-21-02
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
092608A 2008-2009 Edge, Explorer, 0.4 Hr.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 8681
Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus,
Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty,
Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14D212 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 151-24
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Parking Assist Control Module > Component Information > Locations > Page 8685
View 151-25
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Parking Assist Control Module > Component Information > Locations > Page 8686
View 151-26
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Parking Assist Control Module > Component Information > Locations > Page 8687
Parking Assist Control Module: Diagrams
C3267
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Parking Assist Control Module > Component Information > Locations > Page 8688
C4014
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Parking Assist Control Module > Component Information > Locations > Page 8689
C4226
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Parking Assist Control Module > Component Information > Locations > Page 8690
Parking Assist Control Module: Service and Repair
PARKING AID MODULE
Removal and Installation
1. Disconnect the parking aid module (PAM) 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 PAM bumper harness from the PAM. 5. Remove the 2 PAM
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 (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Locations
Parking Assist Distance Sensor: Locations
View 151-26
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Locations > Page 8695
View 151-27
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 8698
C4011
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 8699
C4010
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 8700
C4012
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Pedal Positioning Switch > Component Information > Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Pedal Positioning Switch > Component Information > Locations > Page 8704
C2089
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Remote Switch, Audio - Stereo > Component Information > Locations
View 151-16
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 8708
C2208
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module >
Component Information > Locations
View 151-13
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module >
Component Information > Locations > Page 8713
C239
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8718
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8719
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8720
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8721
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8722
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8723
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8724
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8725
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8726
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8727
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8728
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8729
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8730
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8731
Trailer Connector: Connector Views
C439
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8732
C473
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8733
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 (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8734
95-2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8735
95-4
Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, 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 Location Views. See: Locations/Component Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
rear 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 (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component
Information > Service and Repair > Page 8739
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 (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component
Information > Service and Repair > Page 8740
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 (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component
Information > Service and Repair > Page 8741
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 (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component
Information > Service and Repair > Page 8742
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 (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component
Information > Service and Repair > Page 8743
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 (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component
Information > Service and Repair > Page 8744
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 or pull together the frame rails slightly to get the
brackets to fit.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component
Information > Service and Repair > Page 8745
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 (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8750
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8751
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8752
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8753
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8754
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8755
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8756
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8757
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8758
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8759
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8760
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8761
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8762
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8763
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
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Information > Diagrams > Diagram Information and Instructions > Page 8764
95-2
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Information > Diagrams > Diagram Information and Instructions > Page 8765
95-4
Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, 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 Location Views. See: Locations/Component Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Principles of Operation
PRINCIPLES OF OPERATION
NOTE: The smart junction box (SJB) is also known as the generic electronic module (GEM).
The SJB uses existing inputs to determine if voltage needs to be supplied to the individual trailer
stop/turn lamps. The SJB has separate drivers that provide voltage for the trailer turn lamps. The
trailer parking and reversing lamps share the vehicle lighting outputs.
The vehicle is supplied with wiring to support an aftermarket trailer brake control (TBC) module.
The trailer tow battery charging is controlled by a relay. When the ignition switch is in the RUN or
ACC position, the trailer tow battery charge relay is energized, which routes voltage to the trailer
tow connector.
Field-Effect Transistor (FET) Protection
The SJB utilizes a FET protective circuit strategy for many of its outputs (for example, the
headlamp output circuit). Output loads (current level) are monitored for excessive current (typically
short circuits) and are shut down (turns off the voltage or ground provided by the module) when a
fault is detected. A continuous DTC is stored at the time of the fault. The circuit then resets after a
customer demand of the function (switching the component on, battery saver being energized).
When an excessive circuit load occurs several times, the module shuts down the output until a
repair procedure is carried out. At the same time, the continuous DTC that was stored on the first
failure cannot be cleared by a command to clear the continuous DTCs. The module does not allow
this code to be cleared or the circuit restored to normal until a successful on-demand self-test
proves that the fault has been repaired. After the on-demand self-test has successfully completed
(no on-demand DTCs present), the continuous DTC clears and the circuit function returns.
Each circuit has 3 predefined levels of short circuit tolerance established in the module based on
each circuits' capability. When the first or second level is reached, the continuous DTC associated
with the circuit sets along with DTC B106E. These DTCs may be cleared using the Clear DTC
operation on the scan tool as long as the fault itself has been corrected. If any of the circuits are
shorted past the third level, then B106F and B1342 set along with the associated continuous DTC.
These DTCs cannot be cleared and the module must be replaced.
The SJB FET protected output circuits for the trailer lamp system are the LH and RH trailer
stop/turn output circuits.
Inspection and Verification
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 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 (TBC) 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)
- Circuity
- Trailer
- SJB
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).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8768
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
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 DTC Charts. 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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8769
B2070
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8770
Trailer Lamps: Symptom Related Diagnostic Procedures
Symptom Chart (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8771
Symptom Chart (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8772
Trailer Lamps: Pinpoint Tests
Test W: All The Trailer Lamps Are Inoperative
PINPOINT TEST W: ALL THE TRAILER LAMPS ARE INOPERATIVE
Normal Operation
Ground for the all trailer lamps is provided through circuit RAT08 (WH).
This pinpoint test is intended to diagnose the following:
- Wiring, terminals or connectors
- Trailer tow connector
- Trailer
W1
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W1-W2
Test X: The Trailer Lamps Are Inoperative - Parking Lamps
PINPOINT TEST X: THE TRAILER LAMPS ARE INOPERATIVE - PARKING
Normal Operation
When the vehicle parking lamps are on, the smart junction box (SJB) provides voltage to the trailer
parking lamps through circuit CAT17 (BN).
This pinpoint test is intended to diagnose the following:
- Fuse
- Wiring, terminals or connectors
- Trailer tow connector
- Trailer
- SJB
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8774
X1-X2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8775
X2-X4
Test Y: The Trailer Lamps Are Inoperative - Reversing Lamps
PINPOINT TEST Y: THE TRAILER LAMPS ARE INOPERATIVE - REVERSING LAMPS
Normal Operation
Voltage to the trailer reversing lamps is supplied by the smart junction box (SJB) through circuit
CAT16 (GY/BN).
This pinpoint test is intended to diagnose the following:
- Fuse
- Wiring, terminals or connectors
- Trailer tow connector
- Trailer
- SJB
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8776
Y1-Y3
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8777
Y3-Y4
Test Z: The Individual Trailer Lamp Is Inoperative - LH Stop/Turn Lamp
PINPOINT TEST Z: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - LH STOP/TURN LAMP
Normal Operation
Voltage to the LH trailer stop/turn lamp is supplied by the smart junction box (SJB) through circuit
CAT06 (YE).
- DTC B2070 (Trailer Tow Relay Coil(s) Circuit Failure) - is a continuous DTC that sets when the
SJB detects a short to ground from the LH trailer stop/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 trailer stop/turn
lamp voltage supply. A trailer equipped with too many LH stop/turn bulbs may also set the DTC.
This pinpoint test is intended to diagnose the following:
- Trailer equipped with too many bulbs
- Wiring, terminals or connectors
- Trailer tow connector
- Trailer
- SJB
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8778
Z1-Z6
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8779
Z6-Z7
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8780
Z8-Z9
Tests AA: The Individual Trailer Lamp Is Inoperative - RH Stop/Turn Lamp
PINPOINT TEST AA: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - RH STOP/TURN
LAMP
Normal Operation
Voltage to the RH trailer stop/turn lamp is supplied by the smart junction box (SJB) through circuit
CAT09 (GN).
- DTC B2070 (Trailer Tow Relay Coil(s) Circuit Failure) - is a continuous DTC that sets when the
SJB detects a short to ground from the RH trailer stop/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 trailer stop/turn
lamp voltage supply. A trailer equipped with too many RH stop/turn bulbs may also set the DTC.
This pinpoint test is intended to diagnose the following:
- Trailer equipped with too many bulbs
- Wiring, terminals or connectors
- Trailer tow connector
- Trailer
- SJB
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8781
AA1-AA6
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8782
AA6-AA7
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8783
AA8-AA9
Tests AB: The Trailer Lamps Are On Continuously
PINPOINT TEST AB: THE TRAILER LAMPS ARE ON CONTINUOUSLY
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.
The trailer tow parking lamps share the same voltage supply with the vehicle parking lamps.
This pinpoint test is intended to diagnose the following:
- Wiring, terminals or connectors
- Trailer
- SJB
AB1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8784
AB1-AB3
Tests AC: The Trailer Battery Charging Is Inoperative/Does Not Operate Correctly
PINPOINT TEST AC: THE TRAILER BATTERY CHARGING IS INOPERATIVE/DOES NOT
OPERATE CORRECTLY
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 switch 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).
This pinpoint test is intended to diagnose the following:
- Fuse
- Wiring, terminals or connectors
- Trailer battery charge relay
- Trailer tow connector
- Trailer
- SJB
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8785
AC1-AC3
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8786
AC3-AC4
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8787
AC5-AC6
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8788
AC6 Continued
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8789
AC7-AC9
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8790
AC9-AC11
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8791
AC11-AC12
Tests AD: The Trailer Electric Brakes Are Inoperative/Do Not Operate Correctly
PINPOINT TEST AD: THE TRAILER ELECTRIC BRAKES ARE INOPERATIVE/DO NOT
OPERATE CORRECTLY
Normal Operation
The trailer brake control (TBC) module is provided voltage at all times by the battery junction box
(BJB) fuse 17 (30A) through circuit SBB17 (RD). Ground for the TBC module is provided through
circuit GD138 (BK/WH). The TBC module receives voltage from the stoplamp switch through circuit
CCB08 (VT/WH) when the brake pedal is applied. When requested, the TBC module provides
voltage to the trailer tow connector through circuit CAT19 (BU).
This pinpoint test is intended to diagnose the following:
- Fuse
- Wiring, terminals or connectors
- TBC module
- Trailer tow connector
- Trailer
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AD1-AD3
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AD3-AD5
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AD6-AD8
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AD8-AD9
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Special Tool(s)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Locations > Page 8800
Trailer Lighting Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay >
Component Information > Locations > Page 8804
Trailer Towing Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
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> Diagram Information and Instructions > Page 8809
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
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> Diagram Information and Instructions > Page 8810
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
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> Diagram Information and Instructions > Page 8811
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
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> Diagram Information and Instructions > Page 8812
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8813
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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> Diagram Information and Instructions > Page 8814
Symbols (Part 4)
Symbols (Part 5)
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> Diagram Information and Instructions > Page 8815
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 terminal by pulling each wire at the end of the connector.
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> Diagram Information and Instructions > Page 8816
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
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> Diagram Information and Instructions > Page 8817
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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> Diagram Information and Instructions > Page 8818
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8819
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8820
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8821
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8822
Trailer Connector: Connector Views
C439
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8823
C473
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8824
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 (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8825
95-2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8826
95-4
Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, 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 Location Views. See: Locations/Component Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > Specifications
Torque Specifications
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > Specifications > Page 8831
Body Control Systems: Description and Operation
MODULE CONTROLLED FUNCTIONS
NOTE: The smart junction box (SJB) is also known as the generic electronic module (GEM).
The 2 multifunction electronic control modules on this vehicle are:
- Driver seat module (DSM)
- Smart junction box (SJB)
Driver Seat Module (DSM)
The driver seat module (DSM) is located under the driver seat. The DSM controls the memory
functions of the memory seat positions, and the adjustable pedals. The memory driver seat feature
allows the driver to program a personalized seat position that can be recalled using the memory
switches or the remote keyless entry (RKE) transmitter.
Smart Junction Box (SJB)
The SJB is a combination of a multifunction control module and an interior junction box. The SJB
functions control multiple systems, which include: Accessory delay
- Battery saver
- Exterior lighting
- Heated rear window and mirrors
- Horn
- Illuminated entry and interior lighting
- Power door locks
- RKE system/keyless entry keypad
- Tire pressure monitoring system (TPMS)
- Warning chimes
- Windshield wiper
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview
Body Control Systems: Initial Inspection and Diagnostic Overview
Inspection and Verification
INSPECTION AND VERIFICATION
1. Verify the customer concern. 2. Visually inspect for obvious signs of electrical damage.
VISUAL INSPECTION CHART
Electrical Battery junction box (BJB) fuse 14 (30A)
- Smart junction box (SJB) fuse 1 (20A)
- Wiring, terminals or connectors
- SJB
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
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 DSM. 9. If the DTCs
retrieved are related to the concern, refer to the Diagnostic Trouble Code (DTC) Chart. See:
Diagnostic Trouble Code Descriptions
10. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related
Diagnostic Procedures/Driver Seat Module (DSM)
Principles of Operation
PRINCIPLES OF OPERATION
The DSM controls the memory driver seat positions and the memory adjustable pedals. The DSM
receives inputs from the memory set switches in order to program the 2 separate, personalized
memory positions for the seats and (if equipped) the adjustable pedals. These positions can be
recalled by either pressing the memory switches or by unlocking the vehicle with the remote
transmitters.
The DSM also receives inputs from the driver seat switch and outputs the requested command to
the seats. If the vehicle has memory, the DSM will also receive inputs from the adjustable pedal
switch and outputs the requested commands to the adjustable pedal motor. The memory driver
seat feature allows the driver to program a personalized seat position that can be recalled using the
memory switches or the remote keyless entry (RKE) transmitter. Refer to Locks for the remote
memory activation general procedure.
The DSM is on the medium speed controller area network (MS-CAN). The DSM supports
intermodule and scan tool communications.
Inspection and Verification
INSPECTION AND VERIFICATION
1. Verify the customer concern. 2. Visually inspect for obvious signs of electrical damage.
VISUAL INSPECTION CHART
Electrical
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 8834
- Battery junction box (BJB) fuses: 1 (50A)
- 2 (50A)
- 3 (50A)
- Smart junction box (SJB) fuse 2 (5A)
- Wiring, terminals or connectors
- SJB
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
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 SJB. 9. If the DTCs
retrieved are related to the concern, refer to the Diagnostic Trouble Code (DTC) Chart. See:
Diagnostic Trouble Code Descriptions
10. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related
Diagnostic Procedures/Smart Junction Box (SJB)
Principles of Operation
PRINCIPLES OF OPERATION
NOTE: The smart junction box (SJB) is also known as the generic electronic module (GEM).
The SJB receives inputs and delivers outputs to electronically-controlled features of the vehicle.
The SJB constantly monitors the systems under its control and reports a concern in the form of a
DTC. The DTC can be retrieved with a scan tool through the medium speed controller area network
(MS-CAN).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 8835
Body Control Systems: Diagnostic Trouble Code Descriptions
B106A-B1119
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 8836
B111F-B1178
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 8837
B1200-B1317
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 8838
B1317-B1342
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 8839
B1342-B1485
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 8840
B1499-B1688
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 8841
B1696-B1957
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 8842
B1960-B2051
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 8843
B2070-B2266
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 8844
B229A-B2439
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 8845
B2477-B2505
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 8846
B2507-B2817
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 8847
B287A-B2987 / C1095
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 8848
C1145-C1707
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 8849
C1708-C2278
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 8850
C2780 / P062F-P0712
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 8851
P0713-P0741
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 8852
P0743-P0963
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 8853
P0963-P1705
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 8854
P1707-P2763
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 8855
P2764 / U0073-U0184
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 8856
U0193-U1900
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 8857
U1900-U2050
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 8858
U2050-U2511
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial
Inspection and Diagnostic Overview > Page 8859
Body Control Systems: Symptom Related Diagnostic Procedures
Symptom Chart
Symptom Chart
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > Tools and Equipment > Driver
Seat Module (DSM)
Special Tool(s)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > Tools and Equipment > Driver
Seat Module (DSM) > Page 8862
Special Tool(s)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Module >
Component Information > Locations
View 151-24
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Module >
Component Information > Locations > Page 8867
Auxiliary Step / Running Board Module: Diagrams
C4322A
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Module >
Component Information > Locations > Page 8868
C4322B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Module >
Component Information > Locations > Page 8869
Auxiliary Step / Running Board Module: Service and Repair
POWER RUNNING BOARD (PRB) MODULE
Removal and Installation
1. Remove the RH C-pillar trim panel. 2. Disconnect the power running board (PRB) module
electrical connectors. 3. Remove the 3 screws and the PRB module assembly.
- To install, tighten to 7 Nm (62 lb-in).
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor >
Component Information > Locations > Running Board Motor, Left
View 151-20
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor >
Component Information > Locations > Running Board Motor, Left > Page 8874
View 151-24
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor >
Component Information > Diagrams > Running Board Motor, Left > Page 8877
C3186
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor >
Component Information > Diagrams > Page 8878
Auxiliary Step / Running Board Motor: Service and Repair
POWER RUNNING BOARD (PRB) MOTOR
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist.
2. NOTE: If the power running board (PRB) cannot be extracted, extend the running board by
hand.
Extend the PRB.
3. Remove the straps and disconnect the PRB motor electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor >
Component Information > Diagrams > Page 8879
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 PRB motor.
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 or
patch materials 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 cloth patch per manufacturer's instructions and apply to the affected
area.
- Immediately position the plastic repair material patch 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. Carry out 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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Service and Repair > Procedures > Page 8886
Front Bumper Cover / Fascia: Removal and Replacement
BUMPER COVER - FRONT
Exploded View
Explorer/Explorer Sport Trac
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Service and Repair > Procedures > Page 8887
Mountaineer
Removal and Installation
Explorer/Explorer Sport Trac
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/Explorer Sport Trac
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.
9. Release the bumper cover-to-fender clips.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Service and Repair > Procedures > Page 8888
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 (V8-4.6L (2008))
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
Exploded View
Explorer/Explorer Sport Trac
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System
Information > Service and Repair > Page 8892
Mountaineer
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 (V8-4.6L (2008))
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 or
patch materials 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 cloth patch per manufacturer's instructions and apply to the affected
area.
- Immediately position the plastic repair material patch 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. Carry out 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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information
> Service and Repair > Procedures > Page 8898
Rear Bumper Cover / Fascia: Removal and Replacement
BUMPER COVER - REAR
Exploded View
Explorer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information
> Service and Repair > Procedures > Page 8899
Mountaineer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information
> Service and Repair > Procedures > Page 8900
Explorer Sport Trac
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. Disconnect the rear parking aid sensor
electrical connector, if equipped.
5. CAUTION: To avoid damaging the rear bumper cover, do not twist the cover when removing.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information
> Service and Repair > Procedures > Page 8901
Remove the bumper cover. Lift the outer corners upward and pull the bumper cover straight up and out.
6. Transfer components as necessary. 7. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair
Cowl Moulding / Trim: Service and Repair
COWL PANEL GRILLE
Exploded View
Explorer/Explorer Sport Trac
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair >
Page 8906
Mountaineer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair >
Page 8907
Removal and Installation
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 (V8-4.6L (2008))
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
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front
Door Exterior Handle > System Information > Service and Repair > Page 8915
Part 2
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 (V8-4.6L (2008))
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
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Page 8919
Part 2
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 (V8-4.6L (2008))
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
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System
Information > Service and Repair > Page 8923
Part 2
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 (V8-4.6L (2008))
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
Exploded View
Explorer And Mountaineer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System
Information > Service and Repair > Page 8927
Explorer Sport Trac
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System
Information > Service and Repair > Page 8928
Removal and Installation
1. Remove the front door trim panel handle bezel cover. 2. Remove the front door trim panel
handle bezel screws. 3. 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.
4. Remove the front door trim panel by lifting upward on the armrest to disengage the panel clips.
5. Disconnect the electrical connectors. 6. Disconnect the lock rod cable from the front door trim
panel. 7. Disconnect the door handle conduit and cable from the front door trim panel. 8. To install,
reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 screws.
2. Adjust the door latch striker plate from side-to-side or up and down as necessary.
3. Tighten the door latch striker plate screws.
- Tighten to 25 Nm (18 lb-ft).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 8936
Part 2
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 (V8-4.6L (2008))
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
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor >
Component Information > Service and Repair > Page 8940
Part 2
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 (V8-4.6L (2008))
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
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Service and Repair > Page 8944
Part 2
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. Damage to the window
regulator will occur 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.
10. Secure the front door glass in the full UP position with tape.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Service and Repair > Page 8945
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 (V8-4.6L (2008))
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
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Page 8951
Part 2
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 (V8-4.6L (2008))
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
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 > Page 8955
Part 2
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 (V8-4.6L (2008))
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
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System
Information > Service and Repair > Page 8959
Part 2
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 (V8-4.6L (2008))
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
Exploded View
Explorer And Mountaineer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System
Information > Service and Repair > Page 8963
Explorer Sport Trac
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System
Information > Service and Repair > Page 8964
Explorer/Mountaineer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System
Information > Service and Repair > Page 8965
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System
Information > Service and Repair > Page 8966
9. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 8971
Part 2
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 (V8-4.6L (2008))
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
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor >
Component Information > Service and Repair > Page 8975
Part 2
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 (V8-4.6L (2008))
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
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator
> System Information > Service and Repair > Page 8979
Part 2
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. Damage to the window
regulator will occur 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 rear window
regulator mounting 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 (V8-4.6L (2008))
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
Exploded View
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information >
Service and Repair > Page 8984
- 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 (V8-4.6L (2008))
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
Exploded View
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 (V8-4.6L (2008))
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. NOTE: Open and support the liftgate window glass before removing the liftgate window glass
struts.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass >
Component Information > Service and Repair > Page 8992
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Actuator > Component Information > Locations > Liftgate Glass Actuator
View 151-35
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Actuator > Component Information > Locations > Liftgate Glass Actuator > Page 8997
View 151-35
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Actuator > Component Information > Diagrams > Liftgate Glass Actuator > Page 9000
C457
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 9003
Part 2
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 (V8-4.6L (2008))
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 9004
Power Trunk / Liftgate Lock Actuator: Service and Repair Liftgate Window Latch Actuator
LIFTGATE WINDOW LATCH ACTUATOR
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 9005
Part 2
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Switch > Component Information > Locations
View 151-35
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Switch > Component Information > Locations > Page 9009
C4039
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Ajar Switch >
Component Information > Locations
View 151-35
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Ajar Switch >
Component Information > Locations > Page 9013
C479
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle >
Component Information > Service and Repair > Page 9017
Part 2
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 (V8-4.6L (2008))
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
Exploded View
Explorer And Mountaineer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim
Panel > Component Information > Service and Repair > Page 9021
Explorer Sport Trac
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim
Panel > Component Information > Service and Repair > Page 9022
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 (V8-4.6L (2008))
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
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Service and Repair > Liftgate Latch > Page 9027
Part 2
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Service and Repair > Liftgate Latch > Page 9028
Trunk / Liftgate Latch: Service and Repair Liftgate Window Latch
LIFTGATE WINDOW LATCH
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Service and Repair > Liftgate Latch > Page 9029
Part 2
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 (V8-4.6L (2008))
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
Exploded View
Explorer/Explorer Sport Trac
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information >
Service and Repair > Page 9034
Mountaineer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information >
Service and Repair > Page 9035
Removal and Installation
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 (V8-4.6L (2008))
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
Exploded View
Explorer/Explorer Sport Trac
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service
and Repair > Page 9041
Mountaineer
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. 4. Position the front fender moulding aside and
remove the splash shield lower screw.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service
and Repair > Page 9042
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Description and Operation
Body / Frame Mount Bushing: Description and Operation
Frame and Body Mounting
The frame consists of 2 steel-channel rails, 10 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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Description and Operation > Page 9047
Structural Enhancement - Explorer Sport Trac
The purpose of these inserts is to enhance the structural rigidity of the frame in this area. Inserts
cannot be repaired or installed new.
CAUTION: When removing upper body mounts, enough adjacent body mount support bolts and
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Description and Operation > Page 9048
Body Support - Front End Sheet Metal
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Description and Operation > Page 9049
Body Support - No. 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Description and Operation > Page 9050
Body Support - No. 2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Description and Operation > Page 9051
Body Support - No. 3 (Explorer/Mountaineer ONLY)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Description and Operation > Page 9052
Body Support - No. 3 (Explorer Sport Trac ONLY)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Description and Operation > Page 9053
Body Support - No. 4 (Explorer/Mountaineer ONLY)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Specifications
Cross-Member: Specifications
Torque Specifications
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair >
Transmission Support Crossmember
Cross-Member: Service and Repair Transmission Support Crossmember
Transmission Support Crossmember
Transmission Support Crossmember
Removal and Installation
1. With the vehicle in NEUTRAL, position it on 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).
3. NOTE: Explorer/Mountaineer shown, Explorer Sport Trac similar.
Remove the heat shield bolt from the RH heat shield.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair >
Transmission Support Crossmember > Page 9059
- 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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair >
Transmission Support Crossmember > Page 9060
Cross-Member: Service and Repair Crossmember - 1B
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 (V8-4.6L (2008))
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
rear 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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page
9064
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page
9065
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page
9066
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page
9067
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page
9068
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page
9069
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 or pull together the frame rails slightly to get the
brackets to fit.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page
9070
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations > Page
9074
Trailer Towing Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Grille > Component Information > Technical Service Bulletins > Page 9088
Grille: Service and Repair
RADIATOR GRILLE
Removal and Installation
1. Remove the front bumper cover. 2. Remove the 2 grille-to-bumper cover screws.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Grille > Component Information > Technical Service Bulletins > Page 9089
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and
Repair > Floor Console
Console: Service and Repair Floor Console
Front
FLOOR CONSOLE - FRONT
Removal and Installation
1. Move the front seats to the full rearward position. 2. Remove the LH and RH front floor console
rear bolts. 3. Position the front seats to the full rearward position. 4. Remove the selector lever
bezel. 5. Open and lift the front floor console stowage door upward. 6. Remove the 2 front floor
console finish panel screws. 7. Remove the front floor console finish panel.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and
Repair > Floor Console > Page 9095
- Disconnect the electrical connector.
8. Disconnect the front floor console electrical connector.
9. Remove the 2 front floor console-to-instrument panel screws.
10. Remove the LH and RH front floor console pushpin retainers. 11. Remove the LH and RH front
floor console extension trim panels. 12. Remove the LH and RH front floor console middle bolts.
13. Remove the front floor console.
- Pull the front floor console toward the rear of the vehicle.
14. To install, reverse the removal procedures.
Rear
FLOOR CONSOLE - REAR
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and
Repair > Floor Console > Page 9096
Removal and Installation
NOTE: The rear floor console bracket does not need to be removed to remove the console.
1. Open the armrest and remove the storage compartment insert. 2. Remove the 4 rear floor
console bolts.
- To install, tighten to 9 Nm (80 lb-in).
3. CAUTION: To prevent damage to the 2 plastic guide pegs located on the bottom of the console,
pull the console straight up when
removing.
Disconnect the electrical connector and remove the rear floor console.
4. CAUTION: To prevent damage to the 2 plastic guide pegs located on the bottom of the console,
install the console straight down until the
pegs are correctly seated in the holes.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and
Repair > Floor Console > Page 9097
Console: Service and Repair Console - Overhead
CONSOLE - OVERHEAD
NOTE: Overhead console with garage door opener storage compartment shown, all other consoles
similar.
Removal and Installation
1. Remove the overhead console screw.
2. Remove the overhead console. 3. Disconnect the overhead console electrical connectors. 4. To
install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 eye protection when servicing a vehicle. Failure to follow this instruction may result in
serious personal injury.
- Never probe the electrical connectors on air bag, safety canopy or side air curtain modules.
Failure to follow this instruction may result in the accidental deployment of these modules, which
increases the risk of serious personal injury or death.
- 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 this
instruction may result in the accidental deployment of the safety canopy and cause serious
personal injury or death.
- To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to
follow this instruction may result in serious personal injury or death.
NOTE: The air bag warning indicator 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.
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 warning indicator for at least 30 seconds.
The air bag warning indicator will remain lit
continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning
indicator does not remain lit continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition switch to OFF.
6. WARNING: Always deplete the backup power supply before repairing or installing any new front
or side air bag supplemental restraint
system (SRS) component and before servicing, removing, installing, adjusting or striking
components near the front or side impact sensors or the restraints control module (RCM). Nearby
components include doors, instrument panel, console, door latches, strikers, seats and hood
latches.
Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and
impact sensor(s).
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Failure to follow these instructions may result in serious personal injury or death in the event of an
accidental deployment.
Disconnect the battery ground cable and wait at least one minute.
Repowering Procedure
1. Turn the ignition switch from OFF to ON. 2. Install RCM fuse 17 (10A) to the SJB and close the
cover.
3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of
any air bag module when the battery is
connected. Failure to follow these instructions may result in serious personal injury in the event of
an accidental deployment. Connect the
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 9103
battery ground cable.
Connect the battery ground cable.
4. 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 warning indicator with the air bag modules installed. The air bag
warning indicator will light continuously for approximately 6 seconds and then turn off. If an SRS
fault is present, the air bag warning indicator will: fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag warning 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 warning 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 warning
indicator and any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the RCM and occupant classification system module (OCSM)
using a scan tool.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 9104
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 eye protection when servicing a vehicle. Failure to follow this instruction may result in
serious personal injury.
- Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear
seam pointed away from the body. Do not set a live air bag module down with the deployment
door/trim cover/tear seam face down. Failure to follow these instructions may result in serious
personal injury in the event of an accidental deployment.
- Never probe the electrical connectors on air bag, safety canopy or side air curtain modules.
Failure to follow this instruction may result in the accidental deployment of these modules, which
increases the risk of serious personal injury or death.
- Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive
load limiting retractors. Failure to follow this instruction may result in the accidental deployment of
the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious
personal injury or death.
- 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.
- To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to
follow this instruction may result in serious personal injury or death.
NOTE: The air bag warning indicator 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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 9105
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 warning indicator for at least 30 seconds.
The air bag warning indicator will remain lit
continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning
indicator does not remain lit continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: Always deplete the backup power supply before repairing or installing any new front
or side air bag supplemental restraint
system (SRS) component and before servicing, removing, installing, adjusting or striking
components near the front or side impact sensors or the restraints control module (RCM). Nearby
components include doors, instrument panel, console, door latches, strikers, seats and hood
latches.
Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and
impact sensor(s).
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Failure to follow these instructions may result in serious personal injury or death in the event of an
accidental deployment.
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.
9. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 9106
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.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 9107
15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat
side air bag module electrical connector.
Explorer and Mountaineer vehicles 16. Release and position aside the passenger side C-pillar trim
panel.
17. Disconnect the passenger side safety canopy module electrical connector.
18. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy module electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 9108
19. Release and position aside the driver side C-pillar trim panel.
20. Disconnect the driver side safety canopy module electrical connector.
21. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy module electrical connector.
Explorer Sport Trac vehicles 22. Remove the driver and passenger side upper C-pillar trim panels.
23. Disconnect the passenger side safety canopy module electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 9109
24. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy module electrical connector.
25. Disconnect the driver side safety canopy module electrical connector.
26. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy module electrical connector.
All vehicles 27. 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 9110
28. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air
bag module electrical connector.
29. Install the RCM fuse 17 (10A) to the SJB. 30. 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. 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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 9111
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.
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 10. Remove the restraint system diagnostic tool from the
vehicle harness side of the driver side safety canopy module electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 9112
11. Connect the driver side safety canopy module electrical connector.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 9113
15. Install the passenger side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
All vehicles 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 9114
19. Connect the LH side passenger air bag module electrical connector.
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 driver air bag module electrical connectors are unique and cannot be reversed
when connected to 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. Damage to the connector or component
may occur.
Connect the driver air bag module electrical connectors as noted in removal.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 9115
24. Install the 2 driver air bag module bolts (1 shown).
- Tighten to 7 Nm (62 lb-in).
25. 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.
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: Make sure no one is in the vehicle and there is nothing blocking or placed in front
of any air bag module when the battery is
connected. Failure to follow these instructions may result in serious personal injury in the event of
an accidental deployment.
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 warning indicator with the air bag modules installed. The air bag
warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag
SRS fault is present, the air bag warning indicator will: fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag warning 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 warning 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 warning
indicator and any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the RCM and occupant classification system module (OCSM)
using a scan tool.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and
Repair > Page 9119
Explorer/Mountaineer (Part 2)
Explorer Sport Trac
Removal and Installation
Explorer and Mountaineer only
1. If equipped, remove the rear entertainment system.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and
Repair > Page 9120
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.
18. Remove the lower air duct.
19. Disconnect the electrical connector located at the C-pillar.
- Release the wiring harness pin-type retainers.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and
Repair > Page 9121
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.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and
Repair > Page 9122
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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
9131
CONDITION
BASIC PART NO. CODE
7804104 D4
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 9137
CONDITION
BASIC PART NO. CODE
7804104 D4
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Cab Rear Trim Panel
Trim Panel: Service and Repair Cab Rear Trim Panel
CAB REAR TRIM PANEL
Exploded View
Explorer And Mountaineer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Cab Rear Trim Panel > Page 9142
Explorer Sport Trac
Removal and Installation
1. Position the second row seat back forward. 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Cab Rear Trim Panel > Page 9143
Remove the rear trim panel.
4. To install, reverse the removal procedures.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Cab Rear Trim Panel > Page 9144
Trim Panel: Service and Repair Pillar Trim
A-Pillar Trim Panel
A-PILLAR TRIM PANEL
Exploded View
Explorer And Mountaineer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Cab Rear Trim Panel > Page 9145
Explorer Sport Trac
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
B-PILLAR LOWER TRIM PANEL
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Cab Rear Trim Panel > Page 9146
Exploded View
Explorer And Mountaineer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Cab Rear Trim Panel > Page 9147
Explorer Sport Trac
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
Exploded View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Cab Rear Trim Panel > Page 9148
Explorer And Mountaineer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Cab Rear Trim Panel > Page 9149
Explorer Sport Trac
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. 4. Remove the B-pillar upper trim panel retaining
clip from the lower right corner of the panel.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Cab Rear Trim Panel > Page 9150
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
Exploded View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Cab Rear Trim Panel > Page 9151
Explorer And Mountaineer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Cab Rear Trim Panel > Page 9152
Explorer Sport Trac
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.
- Be sure the hole on the back of the C-pillar upper trim panel is seated over the upper safety belt
anchor bolt.
D-Pillar Trim Panel
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Cab Rear Trim Panel > Page 9153
D-PILLAR TRIM PANEL
Exploded View
Explorer And Mountaineer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Cab Rear Trim Panel > Page 9154
Explorer Sport Trac
Removal and Installation
Vehicles with third row seating
1. Remove the rear cargo management system.
- Remove the screw.
- Remove the pushpin.
- Remove the system.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Cab Rear Trim Panel > Page 9155
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Cab Rear Trim Panel > Page 9156
Trim Panel: Service and Repair Cowl Side Trim Panel
COWL SIDE TRIM PANEL
Exploded View
Explorer And Mountaineer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Cab Rear Trim Panel > Page 9157
Explorer Sport Trac
Removal and Installation
All vehicles
1. Remove the front door scuff plate.
Passenger side
2. Remove the cowl trim panel.
Driver side
3. Remove the hood release lever.
1. Remove the screw. 2. Remove the hood release lever.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Cab Rear Trim Panel > Page 9158
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Cab Rear Trim Panel > Page 9159
Trim Panel: Service and Repair Quarter Trim Panel
QUARTER TRIM PANEL
Exploded View
Explorer And Mountaineer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Cab Rear Trim Panel > Page 9160
Explorer Sport Trac
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. 5. Remove the luggage compartment assembly
cover, if equipped.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Cab Rear Trim Panel > Page 9161
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 (V8-4.6L (2008))
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
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information >
Service and Repair > Page 9167
Part 2
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Locations
View 151-31
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Locations > Page 9172
C500
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Locations > Page 9173
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 3 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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Locations > Page 9174
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information
> Technical Service Bulletins > Customer Interest for Keyless Entry Transmitter: > 08-12-9 > Jun > 08 > Keyless Entry Transmitter May Not Operate
Keyless Entry Transmitter: Customer Interest Keyless Entry - Transmitter May Not Operate
TSB 08-12-9
06/23/08
INOPERATIVE RKE TRANSMITTER (KEY FOB) - DISCHARGED KEY FOB BATTERY
FORD: 2008 Crown Victoria, Focus, Mustang 2007-2008 F-150 2008 E-Series, Expedition,
Explorer Sport Trac, Explorer, F-Super Duty, Ranger
LINCOLN: 2007-2008 Mark LT
MERCURY: 2008 Grand Marquis, Mountaineer
ISSUE Some 2007-2008 vehicles equipped with a remote keyless entry (RKE) transmitter may
exhibit an inoperative Key Fob due to a discharged Key Fob battery. This may be caused by an
internal issue with the Key Fob software. This concern only applies to vehicles built within a specific
date range with Key Fobs manufactured within a specific date range.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
PERFORMING THIS PROCEDURE WILL HAVE NO EFFECT ON KEY FOB RANGE. REFER TO
WORKSHOP MANUAL (WSM), SECTION 501-14 FOR KEY FOB RANGE DIAGNOSTICS.
1. Refer to vehicle list for build date range. (Figure 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information
> Technical Service Bulletins > Customer Interest for Keyless Entry Transmitter: > 08-12-9 > Jun > 08 > Keyless Entry Transmitter May Not Operate > Page 9183
a. If the vehicle was built within the date range, then continue with this procedure.
b. If not, then do not proceed. Continue with normal diagnostics per WSM, Section 501-14.
2. Is the vehicle Key Fob part number 8L3T-15K601-AA (3 button) or 8S4T-15K601-AA (4 button)?
(Figure 2)
a. Yes - Go to Step 3.
b. No - Do not proceed. Continue with normal diagnostics per WSM, Section 501-14.
3. Using a thin coin, open the Key Fob and inspect manufacturer's date code sticker. The first three
digits = day of year. The last digit = year. (Figure 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information
> Technical Service Bulletins > Customer Interest for Keyless Entry Transmitter: > 08-12-9 > Jun > 08 > Keyless Entry Transmitter May Not Operate > Page 9184
a. If the first 3 digits are equal to or between 005 and 306 (5th day through 306th day) and the last
digit is 7 (year), then proceed to Step 4.
b. If the number is outside this specified range, then do not proceed. Continue with normal
diagnostics per WSM, Section 501-14.
4. If the Key Fob is inoperative due to a discharged Key Fob battery, and the date code falls within
the specified range, then replace Key Fob. Program the new Key Fob transmitter using the IDS
RKE Transmitter Programming Procedure. Reassemble old Key Fob for warranty return analysis.
NOTE
KEY FOBS REPLACED UNDER WARRANTY WILL BE REQUESTED FOR ANALYSIS AND
VERIFICATION OF THE DATE CODE.
a. IDS RKE Transmitter Programming Procedure
(1) Install known good battery into the suspect Key Fob so that IDS scan tool can identify it.
(2) Connect IDS to vehicle.
(3) From the Main Toolbox tab:
(a) Select - Body.
(b) Select - Security.
(c) Select - Remote Keyless Entry.
(4) Press the "Unlock" button on the suspect Key Fob to view the Transmitter Identification Code
(TIC) in IDS.
5. Select "Erase One Key Fob" or the "Erase" button.
6. Select the suspect Key Fob TIC to erase from vehicle memory.
7. Remove battery from suspect Key Fob and reassemble for warranty return.
8. Select "Reprogram a New Keyfob" or the "Program" button.
9. Press the "Unlock" button on the NEW Key Fob.
10. Follow the instructions on the scan tool screen to complete the programming procedure.
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
081209A 2008 Focus, Mustang, 0.3 Hr.
Explorer, Explorer Sport Trac, Mountaineer, E-Series, Expedition, Crown Victoria, Grand Marquis,
Ranger, F-Super Duty: Replace Key Fob(s), Includes Time To Perform Key Fob Programming
Procedure, And Verify Date Code Sticker (Do Not Use With 15601A)
081209A 2007-2008 F-150, Mark 0.3 Hr.
LT: Replace Key Fob(s), Includes Time To Perform Key Fob Programming Procedure, And Verify
Date Code Sticker (Do Not Use With 15601A)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information
> Technical Service Bulletins > Customer Interest for Keyless Entry Transmitter: > 08-12-9 > Jun > 08 > Keyless Entry Transmitter May Not Operate > Page 9185
DEALER CODING
CONDITION
BASIC PART NO. CODE
15K601 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 08-12-9 > Jun > 08 >
Keyless Entry - Transmitter May Not Operate
Keyless Entry Transmitter: All Technical Service Bulletins Keyless Entry - Transmitter May Not
Operate
TSB 08-12-9
06/23/08
INOPERATIVE RKE TRANSMITTER (KEY FOB) - DISCHARGED KEY FOB BATTERY
FORD: 2008 Crown Victoria, Focus, Mustang 2007-2008 F-150 2008 E-Series, Expedition,
Explorer Sport Trac, Explorer, F-Super Duty, Ranger
LINCOLN: 2007-2008 Mark LT
MERCURY: 2008 Grand Marquis, Mountaineer
ISSUE Some 2007-2008 vehicles equipped with a remote keyless entry (RKE) transmitter may
exhibit an inoperative Key Fob due to a discharged Key Fob battery. This may be caused by an
internal issue with the Key Fob software. This concern only applies to vehicles built within a specific
date range with Key Fobs manufactured within a specific date range.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
PERFORMING THIS PROCEDURE WILL HAVE NO EFFECT ON KEY FOB RANGE. REFER TO
WORKSHOP MANUAL (WSM), SECTION 501-14 FOR KEY FOB RANGE DIAGNOSTICS.
1. Refer to vehicle list for build date range. (Figure 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 08-12-9 > Jun > 08 >
Keyless Entry - Transmitter May Not Operate > Page 9191
a. If the vehicle was built within the date range, then continue with this procedure.
b. If not, then do not proceed. Continue with normal diagnostics per WSM, Section 501-14.
2. Is the vehicle Key Fob part number 8L3T-15K601-AA (3 button) or 8S4T-15K601-AA (4 button)?
(Figure 2)
a. Yes - Go to Step 3.
b. No - Do not proceed. Continue with normal diagnostics per WSM, Section 501-14.
3. Using a thin coin, open the Key Fob and inspect manufacturer's date code sticker. The first three
digits = day of year. The last digit = year. (Figure 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 08-12-9 > Jun > 08 >
Keyless Entry - Transmitter May Not Operate > Page 9192
a. If the first 3 digits are equal to or between 005 and 306 (5th day through 306th day) and the last
digit is 7 (year), then proceed to Step 4.
b. If the number is outside this specified range, then do not proceed. Continue with normal
diagnostics per WSM, Section 501-14.
4. If the Key Fob is inoperative due to a discharged Key Fob battery, and the date code falls within
the specified range, then replace Key Fob. Program the new Key Fob transmitter using the IDS
RKE Transmitter Programming Procedure. Reassemble old Key Fob for warranty return analysis.
NOTE
KEY FOBS REPLACED UNDER WARRANTY WILL BE REQUESTED FOR ANALYSIS AND
VERIFICATION OF THE DATE CODE.
a. IDS RKE Transmitter Programming Procedure
(1) Install known good battery into the suspect Key Fob so that IDS scan tool can identify it.
(2) Connect IDS to vehicle.
(3) From the Main Toolbox tab:
(a) Select - Body.
(b) Select - Security.
(c) Select - Remote Keyless Entry.
(4) Press the "Unlock" button on the suspect Key Fob to view the Transmitter Identification Code
(TIC) in IDS.
5. Select "Erase One Key Fob" or the "Erase" button.
6. Select the suspect Key Fob TIC to erase from vehicle memory.
7. Remove battery from suspect Key Fob and reassemble for warranty return.
8. Select "Reprogram a New Keyfob" or the "Program" button.
9. Press the "Unlock" button on the NEW Key Fob.
10. Follow the instructions on the scan tool screen to complete the programming procedure.
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
081209A 2008 Focus, Mustang, 0.3 Hr.
Explorer, Explorer Sport Trac, Mountaineer, E-Series, Expedition, Crown Victoria, Grand Marquis,
Ranger, F-Super Duty: Replace Key Fob(s), Includes Time To Perform Key Fob Programming
Procedure, And Verify Date Code Sticker (Do Not Use With 15601A)
081209A 2007-2008 F-150, Mark 0.3 Hr.
LT: Replace Key Fob(s), Includes Time To Perform Key Fob Programming Procedure, And Verify
Date Code Sticker (Do Not Use With 15601A)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 08-12-9 > Jun > 08 >
Keyless Entry - Transmitter May Not Operate > Page 9193
DEALER CODING
CONDITION
BASIC PART NO. CODE
15K601 42
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information
> Testing and Inspection > Remote Keyless Entry Transmitter Programming > Page 9196
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information
> Testing and Inspection > Remote Keyless Entry Transmitter Programming > Page 9197
Keyless Entry Transmitter: Testing and Inspection Stepped Unlock Programming
STEPPED UNLOCK PROGRAMMING
1. With the ignition switch in the OFF position, press the LOCK and UNLOCK buttons on the
remote keyless entry (RKE) transmitter
simultaneously for 4 seconds. The parking lamps will flash twice to indicate the mode change.
2. Repeat STEP 1 to enable/disable the stepped unlocking feature.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information
> Service and Repair > Remote Memory Activation
Keyless Entry Transmitter: Service and Repair 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information
> Service and Repair > Remote Memory Activation > Page 9200
Keyless Entry Transmitter: Service and Repair 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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Locations > Door Lock Actuator, Driver Side
View 151-31
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Locations > Door Lock Actuator, Driver Side > Page 9206
View 151-32
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Locations > Door Lock Actuator, Driver Side > Page 9207
View 151-33
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Locations > Door Lock Actuator, Driver Side > Page 9208
View 151-34
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Diagrams > Door Lock Actuator, Driver Side > Page 9211
C603
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Diagrams > Door Lock Actuator, Driver Side > Page 9212
C704
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Diagrams > Door Lock Actuator, Driver Side > Page 9213
C804
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Service and Repair > Front Door Lock Actuator > Page 9216
Part 2
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Service and Repair > Front Door Lock Actuator > Page 9217
Power Door Lock Actuator: Service and Repair Rear Door Lock Actuator
REAR DOOR LOCK ACTUATOR
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Service and Repair > Front Door Lock Actuator > Page 9218
Part 2
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Locations > Door Lock Switch, Passenger Side
View 151-32
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Locations > Door Lock Switch, Passenger Side > Page 9223
View 151-31
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Diagrams > Door Lock Switch, Driver Side > Page 9226
C605
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Diagrams > Page 9227
Power Door Lock Switch: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Diagrams > Page 9228
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Diagrams > Page 9229
- Release the 4 retaining tabs.
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module >
Component Information > Locations
View 151-28
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module >
Component Information > Locations > Page 9235
Memory Positioning Module: Diagrams
C341A
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module >
Component Information > Locations > Page 9236
C341B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module >
Component Information > Locations > Page 9237
C341C
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module >
Component Information > Locations > Page 9238
Memory Positioning Module: Service and Repair
DRIVER SEAT MODULE (DSM)
Special Tool(s)
Special Tool(s)
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module >
Component Information > Locations > Page 9239
Part 2
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. NOTE: This step is necessary only if the DSM is being replaced.
Upload the module configuration information from the DSM.
2. Remove the driver seat. 3. Remove the 2 DSM screws. 4. Disconnect the electrical connectors
and remove the DSM.
5. NOTE: Once the module is installed (if it was replaced) 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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component
Information > Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component
Information > Locations > Page 9243
C2094
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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. 3. Disconnect the
exterior mirror motor electrical connectors.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Service and Repair
> Page 9247
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations
View 151-31
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page
9251
C527
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page
9252
Power Mirror Switch: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page
9253
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page
9254
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes
Paint: Application and ID Paint Codes
VEHICLE CERTIFICATION (VC) CODES
Vehicle Certification (VC) Label Locator
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes > Page 9260
The VC label contains information on the manufacturer name, the month and year of manufacture,
the certification statement and the VIN. This label also includes GVWR information.
If a vehicle requires replacement of the VC label and is 4 years old or less, an authorized dealer
must submit the VIN to their respective regional office. The regional office will submit a web form to
the assembly plant for the replacement label. Once the label has been printed, a representative
from the regional office will deliver the label to the dealer and witness installation on the vehicle. If a
vehicle is more than 4 years old and requires a replacement label, the dealer must submit a
request to the Department of Motor Vehicles.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes > Page 9261
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
- HH - Dark Cherry - Explorer/Mountaineer/Explorer Sport Trac
- HS - Earth Pearl - 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
- UA - Ebony - Explorer/Mountaineer/Explorer Sport Trac
- WS - White Suede - Explorer/Mountaineer/Explorer Sport Trac
- ZY - Silver Vapor - Explorer/Mountaineer/Explorer Sport Trac
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes > Page 9262
Wheelbase
- 114 - 2,895.6 mm (114 in) - Explorer/Mountaineer
- 131 - 3,327.4 mm (131 in) - Explorer Sport Trac
Interior Trim
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes > Page 9263
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 - Perforated leather seats - Mountaineer
- 4 - Leather with heated driver seat - Mountaineer
- 8 - Embossed leather with suede insert seats - Mountaineer
- I - Leather with power, heated driver and passenger seats- Explorer
- R - Value cloth seats - Explorer
- S - Premium cloth with power driver seat - Explorer/Mountaineer
- T - Leather with power, heated driver seat and memory- Explorer/Explorer Sport Trac
- U - Tracks cloth bucket seats - Explorer Sport Trac
- V - Leather with power driver seat - Explorer
- W - Tracks cloth bucket seats with power driver seat - Explorer Sport Trac
- W - Leather trim with suede inserts and power driver seat - Explorer
- X - Leather trim with suede inserts and power/heated/memory driver seat - Explorer
- Z - Leather with power/heated/memory driver seat - Explorer
Interior Trim Color C - Camel - Explorer/Mountaineer/Explorer Sport Trac
- W - Charcoal Black - Explorer/Mountaineer/Explorer Sport Trac
Tape/Paint Stripe
Tape and paint stripe codes do not apply.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes > Page 9264
Paint: Application and ID Paint Code Sticker Location
VEHICLE CERTIFICATION (VC) CODES
Vehicle Certification (VC) Label Locator
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes > Page 9265
The VC label contains information on the manufacturer name, the month and year of manufacture,
the certification statement and the VIN. This label also includes GVWR information.
If a vehicle requires replacement of the VC label and is 4 years old or less, an authorized dealer
must submit the VIN to their respective regional office. The regional office will submit a web form to
the assembly plant for the replacement label. Once the label has been printed, a representative
from the regional office will deliver the label to the dealer and witness installation on the vehicle. If a
vehicle is more than 4 years old and requires a replacement label, the dealer must submit a
request to the Department of Motor Vehicles.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module >
Component Information > Locations
View 151-28
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module >
Component Information > Locations > Page 9270
Memory Positioning Module: Diagrams
C341A
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module >
Component Information > Locations > Page 9271
C341B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module >
Component Information > Locations > Page 9272
C341C
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module >
Component Information > Locations > Page 9273
Memory Positioning Module: Service and Repair
DRIVER SEAT MODULE (DSM)
Special Tool(s)
Special Tool(s)
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module >
Component Information > Locations > Page 9274
Part 2
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. NOTE: This step is necessary only if the DSM is being replaced.
Upload the module configuration information from the DSM.
2. Remove the driver seat. 3. Remove the 2 DSM screws. 4. Disconnect the electrical connectors
and remove the DSM.
5. NOTE: Once the module is installed (if it was replaced) 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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component
Information > Locations > Third Row Folding Seat Relay, Left
Power Seat Relay: Locations Third Row Folding Seat Relay, Left
View 151-22
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component
Information > Locations > Third Row Folding Seat Relay, Left > Page 9279
View 151-30
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component
Information > Locations > Third Row Folding Seat Relay, Left > Page 9280
Power Seat Relay: Locations Third Row Folding Seat Relay, Right
View 151-22
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component
Information > Locations > Third Row Folding Seat Relay, Left > Page 9281
View 151-30
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 9284
C4184
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Power Seat Relay: Testing and Inspection Third Row Folding Seat Relay, Left
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 9287
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 9288
Power Seat Relay: Testing and Inspection Third Row Folding Seat Relay, Right
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 9289
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Auxiliary Step / Running Board
Module > Component Information > Locations
View 151-24
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Auxiliary Step / Running Board
Module > Component Information > Locations > Page 9293
Auxiliary Step / Running Board Module: Diagrams
C4322A
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Auxiliary Step / Running Board
Module > Component Information > Locations > Page 9294
C4322B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Auxiliary Step / Running Board
Module > Component Information > Locations > Page 9295
Auxiliary Step / Running Board Module: Service and Repair
POWER RUNNING BOARD (PRB) MODULE
Removal and Installation
1. Remove the RH C-pillar trim panel. 2. Disconnect the power running board (PRB) module
electrical connectors. 3. Remove the 3 screws and the PRB module assembly.
- To install, tighten to 7 Nm (62 lb-in).
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module >
Component Information > Locations
Sunroof / Moonroof Module: Locations
View 151-36
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module >
Component Information > Locations > Page 9299
View 151-37
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module >
Component Information > Locations > Page 9300
C921
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component
Information > Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component
Information > Locations > Page 9304
Trailer Towing Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Motor > Component Information > Service and Repair > Page 9310
Part 2
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: Testing and Inspection/Programming and Relearning
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. For additional information, refer to Roof Opening Panel
Motor Initialization. See: Testing and Inspection/Programming and Relearning
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Switch > Component Information > Locations
Sunroof / Moonroof Switch: Locations
View 151-36
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Switch > Component Information > Locations > Page 9314
View 151-37
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Switch > Component Information > Locations > Page 9315
Sunroof / Moonroof Switch: Diagrams
C912
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Switch > Component Information > Locations > Page 9316
C9001
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Switch > Component Information > Locations > Page 9317
C9038
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Switch > Component Information > Testing and Inspection > Roof Opening Panel Switch
Sunroof / Moonroof Switch: Testing and Inspection Roof Opening Panel Switch
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Switch > Component Information > Testing and Inspection > Roof Opening Panel Switch > Page 9320
Sunroof / Moonroof Switch: Testing and Inspection Roof Opening Panel Switch With Rear Window
Motor
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Switch > Component Information > Testing and Inspection > Roof Opening Panel Switch > Page 9321
Sunroof / Moonroof Switch: Testing and Inspection Roof Opening Panel Switch With Medium
Overhead Console
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Switch > Component Information > Testing and Inspection > Page 9322
Sunroof / Moonroof 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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Track > Component Information > Service and Repair
Sunroof / Moonroof Track: Service and Repair
TROUGH ASSEMBLY
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Track > Component Information > Service and Repair > Page 9326
Part 2
Removal and Installation
1. Remove the roof opening panel glass. 2. Remove the trough assembly.
- Pull the trough assembly arms outward to release the trough assembly guide arm pins from the
roof opening panel frame to remove.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Windguard > Component Information > Service and Repair > Page 9330
Part 2
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. For additional information, refer to Roof Opening Panel
Motor Initialization. See: Testing and Inspection/Programming and Relearning
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Service and Repair > Page 9334
Part 2
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: Testing and Inspection/Programming and Relearning
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. 5. Remove the entertainment center support bracket (if equipped).
- Remove the 7 bolts.
- Remove the support bracket.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Service and Repair > Page 9335
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. For additional information, refer to Roof Opening Panel
Motor Initialization. See: Testing and Inspection/Programming and Relearning
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Module > Component Information > Locations
Sunroof / Moonroof Module: Locations
View 151-36
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Module > Component Information > Locations > Page 9339
View 151-37
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Module > Component Information > Locations > Page 9340
C921
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 9345
Part 2
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: Testing and Inspection/Programming and Relearning
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. For additional information, refer to Roof
Opening Panel Alignment. See: Adjustments
- Initialize the roof opening panel motor. For additional information, refer to Roof Opening Panel
Motor Initialization. See: Testing and Inspection/Programming and Relearning
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 9346
Sunroof / Moonroof Panel: Service and Repair Roof Opening Panel Shield
ROOF OPENING PANEL SHIELD
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 9347
Part 2
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.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 9348
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Description and Operation
Child Seat: Description and Operation
ATTACHING SAFETY SEATS WITH TETHER STRAPS
Some manufacturers make child safety seats that include a tether strap that goes over the back of
the vehicle seat and attaches to an anchoring point. Other manufacturers offer the tether strap as
an accessory. Contact the manufacturer of the child safety seat for information about ordering a
tether strap.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module >
Component Information > Locations
View 151-28
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module >
Component Information > Locations > Page 9357
Memory Positioning Module: Diagrams
C341A
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module >
Component Information > Locations > Page 9358
C341B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module >
Component Information > Locations > Page 9359
C341C
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module >
Component Information > Locations > Page 9360
Memory Positioning Module: Service and Repair
DRIVER SEAT MODULE (DSM)
Special Tool(s)
Special Tool(s)
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module >
Component Information > Locations > Page 9361
Part 2
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. NOTE: This step is necessary only if the DSM is being replaced.
Upload the module configuration information from the DSM.
2. Remove the driver seat. 3. Remove the 2 DSM screws. 4. Disconnect the electrical connectors
and remove the DSM.
5. NOTE: Once the module is installed (if it was replaced) 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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component
Information > Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component
Information > Locations > Page 9365
C2094
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Power
Seat Motor Assembly
Power Seat Motor: Locations Power Seat Motor Assembly
View 151-28
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Power
Seat Motor Assembly > Page 9370
View 151-29
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Power
Seat Motor Assembly > Page 9371
Power Seat Motor: Locations Third Row Folding Seat Motor
View 151-30
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Power
Seat Motor Assembly > Page 9372
View 151-30
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Power
Seat Motor Assembly > Page 9373
View 151-28
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver
Seat Recliner Motor
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Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver
Seat Recliner Motor > Page 9376
Power Seat Motor: Diagrams Power Seat Motor Assembly
C353
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver
Seat Recliner Motor > Page 9377
C357
C3015
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver
Seat Recliner Motor > Page 9378
Power Seat Motor: Diagrams Third Row Folding Seat Motor
C4181
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver
Seat Recliner Motor > Page 9379
C4182
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Exploded View
Front Seat Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Seat Recliner Motor > Page 9382
Front Seat Backrest (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Seat Recliner Motor > Page 9383
Driver Seat Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Seat Recliner Motor > Page 9384
Driver Seat Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Seat Recliner Motor > Page 9385
Passenger Seat Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Seat Recliner Motor > Page 9386
Passenger Seat Cushion (Part 2)
Special Tool(s)
Special Tool(s)
Removal
NOTE: The air bag warning indicator 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.
1. Remove the front seat. 2. Remove the front seat backrest. 3. Remove the plastic rivets attaching
the backrest trim cover to the inboard and outboard recliners.
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Seat Recliner Motor > Page 9387
1. NOTE: The recliners are synchronized. Do not rotate the recliner shaft until completely installed.
Install the recliner motor in the following sequence. 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Seat Recliner Motor > Page 9388
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Locations > Third
Row Folding Seat Relay, Left
Power Seat Relay: Locations Third Row Folding Seat Relay, Left
View 151-22
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Locations > Third
Row Folding Seat Relay, Left > Page 9393
View 151-30
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Locations > Third
Row Folding Seat Relay, Left > Page 9394
Power Seat Relay: Locations Third Row Folding Seat Relay, Right
View 151-22
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Locations > Third
Row Folding Seat Relay, Left > Page 9395
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Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Diagrams > Third
Row Folding Seat Relay, Left > Page 9398
C4184
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Testing and
Inspection > Third Row Folding Seat Relay, Left
Power Seat Relay: Testing and Inspection Third Row Folding Seat Relay, Left
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Testing and
Inspection > Third Row Folding Seat Relay, Left > Page 9401
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Testing and
Inspection > Third Row Folding Seat Relay, Left > Page 9402
Power Seat Relay: Testing and Inspection Third Row Folding Seat Relay, Right
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Testing and
Inspection > Third Row Folding Seat Relay, Left > Page 9403
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third
Row Folding Seat Switch
Power Seat Switch: Locations Third Row Folding Seat Switch
View 151-22
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third
Row Folding Seat Switch > Page 9408
View 151-30
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third
Row Folding Seat Switch > Page 9409
View 151-22
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third
Row Folding Seat Switch > Page 9410
View 151-30
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third
Row Folding Seat Switch > Page 9411
Power Seat Switch: Locations Power Seat Switch
View 151-28
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third
Row Folding Seat Switch > Page 9412
View 151-29
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Power
Seat Switch
Power Seat Switch: Diagrams Power Seat Switch
C352
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Power
Seat Switch > Page 9415
C3016
C355
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Power
Seat Switch > Page 9416
Power Seat Switch: Diagrams Third Row Folding Seat Switch
C4179
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Power
Seat Switch > Page 9417
C4180
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Power Seat Switch, Left - 10-Way Power Seat
Power Seat Switch: Testing and Inspection Power Seat Switch, Left - 10-Way Power Seat
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Power Seat Switch, Left - 10-Way Power Seat > Page 9420
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Power Seat Switch, Left - 10-Way Power Seat > Page 9421
Power Seat Switch: Testing and Inspection Power Seat Switch, Left - 6-Way Power Seat
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Power Seat Switch, Left - 10-Way Power Seat > Page 9422
Power Seat Switch: Testing and Inspection Power Seat Switch, Right
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Page 9423
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 (V8-4.6L (2008))
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
Exploded View
Front Seat Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9428
Front Seat Backrest (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9429
Driver Seat Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9430
Driver Seat Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9431
Passenger Seat Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9432
Passenger Seat Cushion (Part 2)
Special Tool(s)
Special Tool(s)
Removal and Installation
WARNING: Never probe the electrical connectors on air bag, safety canopy or side air curtain
modules. Failure to follow this instruction may result in the accidental deployment of these
modules, which increases the risk of serious personal injury or death.
NOTE:
- The air bag warning indicator 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.
- Driver shown, passenger similar.
All seats
1. Remove the front seat. 2. Remove the cushion side shield in the following sequence.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9433
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
11. Disconnect the backrest power feed electrical connector and route out the wire harness.
- Release any wire harness retainers.
Passenger seat with heat
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9434
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 shown, passenger similar.
Release the side air bag wire harness pin-type retainers across the back of the cushion frame.
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. 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.
40 Percent E-Z Entry
SEAT BACKREST - SECOND ROW, 40 PERCENT E-Z ENTRY
Exploded View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9435
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9436
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9437
Second Row, 60 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9438
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9439
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9440
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9441
Second Row, Bucket, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9442
Second Row, Bucket, Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9443
Second Row, Bucket, Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9444
Second Row, 60 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9445
Second Row, 60 Percent Bench, Cushion
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9446
Second Row, 40 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9447
Second Row, 40 Percent Bench, Cushion
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 outboard recliner-to-backrest frame bolts.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9448
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: Use care when the seat back frame is removed and when releasing the recliners
from a backrest upright position. The
recliners are spring-loaded, which may cause the recliner upper arms to fold with significant
speed/force. Failure to follow this instruction may result in serious personal injury.
Position the inboard recliner pin to the recliner stop. The recliner pin must contact the inboard recliner outer plate (stop).
4. WARNING: Use care when the seat back frame is removed and when releasing the recliners
from a backrest upright position. The
recliners are spring-loaded, which may cause the recliner upper arms to fold with significant
speed/force. Failure to follow this instruction may result in serious personal injury.
NOTE: If the latch feet are not locked around the strikers on the mounting plate, the recliners will not lock
in position.
- 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).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9449
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.
60 Percent, E-Z Entry
SEAT BACKREST - SECOND ROW, 60 PERCENT, E-Z ENTRY
Exploded View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9450
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9451
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9452
Second Row, 60 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9453
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9454
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9455
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9456
Second Row, Bucket, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9457
Second Row, Bucket, Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9458
Second Row, Bucket, Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9459
Second Row, 60 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9460
Second Row, 60 Percent Bench, Cushion
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9461
Second Row, 40 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9462
Second Row, 40 Percent Bench, Cushion
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 outboard recliner-to-backrest frame bolts.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9463
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: Use care when the seat back frame is removed and when releasing the recliners
from a backrest upright position. The
recliners are spring-loaded, which may cause the recliner upper arms to fold with significant
speed/force. Failure to follow this instruction may result in serious personal injury.
NOTE: An assistant will be necessary for this procedure.
- 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. Each recliner pin must contact the recliner outer plate (stop).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9464
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9465
10. CAUTION: Make sure the safety belt webbing is not twisted prior to installation or damage may
occur.
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.
40 Percent, Bench
SEAT BACKREST - SECOND ROW, 40 PERCENT, BENCH
Exploded View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9466
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9467
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9468
Second Row, 60 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9469
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9470
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9471
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9472
Second Row, Bucket, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9473
Second Row, Bucket, Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9474
Second Row, Bucket, Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9475
Second Row, 60 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9476
Second Row, 60 Percent Bench, Cushion
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9477
Second Row, 40 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9478
Second Row, 40 Percent Bench, Cushion
Removal
1. Release the seat backrest J-clip. 2. Remove all the staples holding the backrest trim cover to the
backrest support panel.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9479
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. 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 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 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.
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.
60 Percent, Bench
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9480
SEAT BACKREST - SECOND ROW, 60 PERCENT, BENCH
Exploded View
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9481
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9482
Second Row, 60 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9483
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9484
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9485
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9486
Second Row, Bucket, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9487
Second Row, Bucket, Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9488
Second Row, Bucket, Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9489
Second Row, 60 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9490
Second Row, 60 Percent Bench, Cushion
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9491
Second Row, 40 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9492
Second Row, 40 Percent Bench, Cushion
Removal
1. Remove the safety belt anchor bolt. 2. Release the seat backrest J-clip. 3. Remove all the
staples holding the backrest trim cover to the backrest support panel.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9493
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. 9. Attach the seat backrest J-clip.
10. Position the safety belt anchor and install the bolt.
- Tighten to 75 Nm (55 lb-ft).
Bucket
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9494
SEAT BACKREST - SECOND ROW, BUCKET
Exploded View
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9495
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9496
Second Row, 60 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9497
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9498
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9499
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9500
Second Row, Bucket, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9501
Second Row, Bucket, Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9502
Second Row, Bucket, Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9503
Second Row, 60 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9504
Second Row, 60 Percent Bench, Cushion
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9505
Second Row, 40 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9506
Second Row, 40 Percent Bench, Cushion
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.
Seat Backrest - Third Row
SEAT BACKREST - THIRD ROW
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9507
Exploded View
Third Row Seat Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9508
Third Row Seat Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9509
Third Row Seat Cushion (Part 2)
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9510
Seat Back: Overhaul
Seat Backrest - Front
SEAT BACKREST - FRONT
Special Tool(s)
Special Tool(s)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9511
Front Seat Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9512
Front Seat Backrest (Part 2)
Disassembly
WARNING: Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear
seam pointed away from the body. Do not set a live air bag module down with the deployment
door/trim cover/tear seam face down. Failure to follow these instructions may result in serious
personal injury in the event of an accidental deployment.
- Never probe the electrical connectors on air bag, safety canopy or side air curtain modules.
Failure to follow this instruction may result in the accidental deployment of these modules, which
increases the risk of serious personal injury or death.
- If the seat side air bag cover has been damaged or separated from its mounting, or if the air bag
material has been exposed, install a new seat side air bag module. Never try to repair the seat side
air bag module. Failure to follow these instructions may result in the seat side air bag deploying
incorrectly, which increases the risk of serious personal injury or death in a crash.
- Front seat backrest trim covers installed on seats equipped with seat side air bags cannot be
repaired. A new trim cover must be installed. Cleaning is permissible. Failure to follow these
instructions may result in the seat side air bag module deploying incorrectly and increase the risk of
serious personal injury or death in a crash.
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.
- The air bag warning indicator 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.
- The manual recliners and power recliners are serviced as part of the backrest frame.
All seats 1. Remove the front seat. 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9513
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 in the following sequence.
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.
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9514
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 seat side air bag module/deployment chute assembly: Inspect the side air bag module and mounting surfaces for any damage or foreign material.
- Remove any foreign material from the mounting surfaces of the deployment chute, the seat
backrest frame mounting bracket and the air bag module cavity in the seat backrest foam pad.
- Install new parts if damaged.
Failure to follow these instructions may result in the seat side air bag deploying incorrectly, which
increases the risk of serious personal injury or death in a crash.
- If the seat side air bag cover has been damaged or separated from its mounting, or if the air bag
material has been exposed, install a new seat side air bag module. Never try to repair the seat side
air bag module. Failure to follow these instructions may result in the seat side air bag deploying
incorrectly, which increases the risk of serious personal injury or death in a crash.
- Inspect the seat side air bag module cavity in the seat backrest foam pad for any foreign material.
If any foreign material is found, remove it. Failure to follow these instructions may result in the seat
side air bag module deploying incorrectly and increases the risk of serious personal injury or death
in a crash.
CAUTION: Make sure the side air bag module wiring harness is not pinched between the side air
bag module and the mounting bracket. Failure to follow this instruction may result in wiring harness
damage.
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.
5. Slide the side air bag module onto the backrest frame so the bracket hook wraps around the
backrest frame.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9515
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.
Passenger seat 18. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight
Test and prove out the SRS.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9516
40 Percent E-Z Entry
SEAT BACKREST - SECOND ROW, 40 PERCENT E-Z ENTRY
Second Row, 40 Percent E-Z Entry Backrest
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9517
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.
60 Percent, E-Z Entry
SEAT BACKREST - SECOND ROW, 60 PERCENT, E-Z ENTRY
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9518
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9519
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Disassembly and Assembly
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.
40 Percent, Bench
SEAT BACKREST - SECOND ROW, 40 PERCENT, BENCH
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9520
Disassembly and Assembly
1. Remove the second row 60 percent seat of the 60/40 bench seat. 2. Remove the second row, 40
percent seat backrest. 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9521
- 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.
60 Percent, Bench
SEAT BACKREST - SECOND ROW, 60 PERCENT, BENCH
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9522
Disassembly and Assembly
1. Remove the second row 60 percent seat of the 60/40 bench seat. 2. Remove the second row, 60
percent seat backrest. 3. Using an appropriate tool, push in the hole of each head restraint guide
while lifting up and remove the head restraint.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9523
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.
Bucket
SEAT BACKREST - SECOND ROW, BUCKET
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9524
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. 7.
To assemble, reverse the disassembly procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9525
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 9526
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 (V8-4.6L (2008))
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
Exploded View
Front Seat Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9531
Front Seat Backrest (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9532
Driver Seat Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9533
Driver Seat Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9534
Passenger Seat Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9535
Passenger Seat Cushion (Part 2)
Special Tool(s)
Special Tool(s)
Removal and Installation
WARNING: Front seat backrest trim covers installed on seats equipped with seat side air bags
cannot be repaired. A new trim cover must be installed. Cleaning is permissible. Failure to follow
these instructions may result in the seat side air bag module deploying incorrectly and increase the
risk of serious personal injury or death in a crash.
NOTE:
- The air bag warning indicator 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.
All seats
1. Remove the front seat. 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9536
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. If a passenger seat has been serviced, do not prove out the SRS at this time.
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9537
Seat Cover: Service and Repair Seat Cushion Cover - Front
SEAT CUSHION COVER - FRONT
Exploded View
Front Seat Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9538
Front Seat Backrest (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9539
Driver Seat Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9540
Driver Seat Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9541
Passenger Seat Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9542
Passenger Seat Cushion (Part 2)
Special Tool(s)
Special Tool(s)
Removal and Installation
NOTE:
- The air bag warning indicator 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.
All seats
1. Remove the front seat. 2. Remove the cushion side shield in the following sequence.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9543
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. 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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9544
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
Exploded View
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9545
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9546
Second Row, 60 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9547
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9548
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9549
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9550
Second Row, Bucket, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9551
Second Row, Bucket, Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9552
Second Row, Bucket, Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9553
Second Row, 60 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9554
Second Row, 60 Percent Bench, Cushion
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9555
Second Row, 40 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9556
Second Row, 40 Percent Bench, Cushion
Removal and Installation
1. Using an appropriate tool, push in the hole of each head restraint guide while lifting up and
remove the head restraint.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9557
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.
60 Percent E-Z Entry
SEAT BACKREST COVER - SECOND ROW, 60 PERCENT, E-Z ENTRY
Exploded View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9558
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9559
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9560
Second Row, 60 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9561
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9562
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9563
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9564
Second Row, Bucket, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9565
Second Row, Bucket, Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9566
Second Row, Bucket, Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9567
Second Row, 60 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9568
Second Row, 60 Percent Bench, Cushion
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9569
Second Row, 40 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9570
Second Row, 40 Percent Bench, Cushion
Removal and Installation
1. Using an appropriate tool, push in the hole of each head restraint guide while lifting up and
remove the head restraint.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9571
2. Remove 2 screws and the inboard recliner outer cover.
3. CAUTION: Make sure the safety belt webbing is not twisted prior to installation. Failure to follow
this instruction may result in
incorrect operation of the safety belt retractor.
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.
40 Percent, Bench
SEAT BACKREST COVER - SECOND ROW, 40 PERCENT, BENCH
Exploded View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9572
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9573
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9574
Second Row, 60 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9575
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9576
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9577
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9578
Second Row, Bucket, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9579
Second Row, Bucket, Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9580
Second Row, Bucket, Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9581
Second Row, 60 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9582
Second Row, 60 Percent Bench, Cushion
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9583
Second Row, 40 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9584
Second Row, 40 Percent Bench, Cushion
Removal and Installation
1. Remove the head restraint. 2. Release the seat backrest J-clip. 3. Remove all the staples
holding the backrest trim cover to the backrest support panel.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9585
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.
60 Percent, Bench
SEAT BACKREST COVER - SECOND ROW, 60 PERCENT, BENCH
Exploded View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9586
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9587
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9588
Second Row, 60 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9589
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9590
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9591
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9592
Second Row, Bucket, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9593
Second Row, Bucket, Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9594
Second Row, Bucket, Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9595
Second Row, 60 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9596
Second Row, 60 Percent Bench, Cushion
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9597
Second Row, 40 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9598
Second Row, 40 Percent Bench, Cushion
Removal and Installation
All vehicles
1. Remove the second row 60 percent seat of the 60/40 bench seat. 2. Using an appropriate tool,
push in the hole of each head restraint guide while lifting up and remove the head restraint.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9599
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.
Sport Trac vehicles
5. Remove the 4 screws and the upper latch cover.
All vehicles
6. Remove the screws and the upper latch cover. 7. Release the backrest trim cover J-clip. 8.
Remove all the staples in the backrest support panel.
9. 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.
10. 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.
11. Separate the hook-and-loop fasteners. Remove the backrest trim cover.
- Feed the safety belt out through the backrest trim cover.
12. To install, reverse the removal procedure.
Bucket
SEAT BACKREST COVER - SECOND ROW, BUCKET
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9600
Exploded View
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9601
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9602
Second Row, 60 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9603
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9604
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9605
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9606
Second Row, Bucket, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9607
Second Row, Bucket, Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9608
Second Row, Bucket, Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9609
Second Row, 60 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9610
Second Row, 60 Percent Bench, Cushion
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9611
Second Row, 40 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9612
Second Row, 40 Percent Bench, Cushion
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 as high as it will go.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9613
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9614
Seat Cover: Service and Repair Seat Cushion Cover - Second Row
40 Percent E-Z Entry
SEAT CUSHION COVER - SECOND ROW, 40 PERCENT E-Z ENTRY
Exploded View
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9615
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9616
Second Row, 60 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9617
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9618
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9619
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9620
Second Row, Bucket, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9621
Second Row, Bucket, Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9622
Second Row, Bucket, Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9623
Second Row, 60 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9624
Second Row, 60 Percent Bench, Cushion
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9625
Second Row, 40 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9626
Second Row, 40 Percent Bench, Cushion
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.
Release the hook-and-loop strips and remove the cushion trim cover from the cushion foam pad.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9627
4. To install, reverse the removal procedure.
60 Percent, E-Z Entry
SEAT CUSHION COVER - SECOND ROW, 60 PERCENT, E-Z ENTRY
Exploded View
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9628
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9629
Second Row, 60 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9630
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9631
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9632
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9633
Second Row, Bucket, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9634
Second Row, Bucket, Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9635
Second Row, Bucket, Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9636
Second Row, 60 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9637
Second Row, 60 Percent Bench, Cushion
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9638
Second Row, 40 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9639
Second Row, 40 Percent Bench, Cushion
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.
Release the hook-and-loop strips and separate the cushion trim cover from the cushion foam pad.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9640
4. To install, reverse the removal procedure.
- After installation, make sure the LATCH and safety belt buckles are accessible to the occupants.
40 Percent, Bench
SEAT CUSHION COVER - SECOND ROW, 40 PERCENT, BENCH
Exploded View
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9641
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9642
Second Row, 60 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9643
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9644
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9645
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9646
Second Row, Bucket, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9647
Second Row, Bucket, Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9648
Second Row, Bucket, Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9649
Second Row, 60 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9650
Second Row, 60 Percent Bench, Cushion
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9651
Second Row, 40 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9652
Second Row, 40 Percent Bench, Cushion
Removal and Installation
1. Remove the second row 40 percent seat of the 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.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9653
60 Percent, Bench
SEAT CUSHION COVER - SECOND ROW, 60 PERCENT, BENCH
Exploded View
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9654
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9655
Second Row, 60 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9656
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9657
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9658
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9659
Second Row, Bucket, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9660
Second Row, Bucket, Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9661
Second Row, Bucket, Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9662
Second Row, 60 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9663
Second Row, 60 Percent Bench, Cushion
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9664
Second Row, 40 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9665
Second Row, 40 Percent Bench, Cushion
Removal and Installation
1. Remove the second row 60 percent seat of the 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.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9666
Bucket
SEAT CUSHION COVER - SECOND ROW, BUCKET
Exploded View
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9667
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9668
Second Row, 60 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9669
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9670
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9671
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9672
Second Row, Bucket, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9673
Second Row, Bucket, Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9674
Second Row, Bucket, Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9675
Second Row, 60 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9676
Second Row, 60 Percent Bench, Cushion
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9677
Second Row, 40 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9678
Second Row, 40 Percent Bench, Cushion
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.
2. Release the cable from the seat riser and remove the cushion trim cover.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9679
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9680
Seat Cover: Service and Repair
Seat Backrest Cover - Front
SEAT BACKREST COVER - FRONT
Exploded View
Front Seat Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9681
Front Seat Backrest (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9682
Driver Seat Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9683
Driver Seat Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9684
Passenger Seat Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9685
Passenger Seat Cushion (Part 2)
Special Tool(s)
Special Tool(s)
Removal and Installation
WARNING: Front seat backrest trim covers installed on seats equipped with seat side air bags
cannot be repaired. A new trim cover must be installed. Cleaning is permissible. Failure to follow
these instructions may result in the seat side air bag module deploying incorrectly and increase the
risk of serious personal injury or death in a crash.
NOTE:
- The air bag warning indicator 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.
All seats
1. Remove the front seat. 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9686
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. If a passenger seat has been serviced, do not prove out the SRS at this time.
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
Exploded View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9687
Front Seat Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9688
Front Seat Backrest (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9689
Driver Seat Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9690
Driver Seat Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9691
Passenger Seat Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9692
Passenger Seat Cushion (Part 2)
Special Tool(s)
Special Tool(s)
Removal and Installation
NOTE:
- The air bag warning indicator 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.
All seats
1. Remove the front seat. 2. Remove the cushion side shield in the following sequence.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9693
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. 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.
40 Percent E-Z Entry
SEAT BACKREST COVER - SECOND ROW, 40 PERCENT E-Z ENTRY
Exploded View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9694
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9695
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9696
Second Row, 60 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9697
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9698
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9699
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9700
Second Row, Bucket, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9701
Second Row, Bucket, Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9702
Second Row, Bucket, Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9703
Second Row, 60 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9704
Second Row, 60 Percent Bench, Cushion
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9705
Second Row, 40 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9706
Second Row, 40 Percent Bench, Cushion
Removal and Installation
1. Using an appropriate tool, push in the hole of each head restraint guide while lifting up and
remove the head restraint.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9707
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.
60 Percent E-Z Entry
SEAT BACKREST COVER - SECOND ROW, 60 PERCENT, E-Z ENTRY
Exploded View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9708
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9709
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9710
Second Row, 60 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9711
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9712
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9713
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9714
Second Row, Bucket, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9715
Second Row, Bucket, Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9716
Second Row, Bucket, Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9717
Second Row, 60 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9718
Second Row, 60 Percent Bench, Cushion
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9719
Second Row, 40 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9720
Second Row, 40 Percent Bench, Cushion
Removal and Installation
1. Using an appropriate tool, push in the hole of each head restraint guide while lifting up and
remove the head restraint.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9721
2. Remove 2 screws and the inboard recliner outer cover.
3. CAUTION: Make sure the safety belt webbing is not twisted prior to installation. Failure to follow
this instruction may result in
incorrect operation of the safety belt retractor.
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.
40 Percent, Bench
SEAT BACKREST COVER - SECOND ROW, 40 PERCENT, BENCH
Exploded View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9722
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9723
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9724
Second Row, 60 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9725
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9726
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9727
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9728
Second Row, Bucket, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9729
Second Row, Bucket, Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9730
Second Row, Bucket, Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9731
Second Row, 60 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9732
Second Row, 60 Percent Bench, Cushion
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9733
Second Row, 40 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9734
Second Row, 40 Percent Bench, Cushion
Removal and Installation
1. Remove the head restraint. 2. Release the seat backrest J-clip. 3. Remove all the staples
holding the backrest trim cover to the backrest support panel.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9735
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.
60 Percent, Bench
SEAT BACKREST COVER - SECOND ROW, 60 PERCENT, BENCH
Exploded View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9736
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9737
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9738
Second Row, 60 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9739
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9740
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9741
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9742
Second Row, Bucket, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9743
Second Row, Bucket, Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9744
Second Row, Bucket, Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9745
Second Row, 60 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9746
Second Row, 60 Percent Bench, Cushion
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9747
Second Row, 40 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9748
Second Row, 40 Percent Bench, Cushion
Removal and Installation
All vehicles
1. Remove the second row 60 percent seat of the 60/40 bench seat. 2. Using an appropriate tool,
push in the hole of each head restraint guide while lifting up and remove the head restraint.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9749
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.
Sport Trac vehicles
5. Remove the 4 screws and the upper latch cover.
All vehicles
6. Remove the screws and the upper latch cover. 7. Release the backrest trim cover J-clip. 8.
Remove all the staples in the backrest support panel.
9. 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.
10. 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.
11. Separate the hook-and-loop fasteners. Remove the backrest trim cover.
- Feed the safety belt out through the backrest trim cover.
12. To install, reverse the removal procedure.
Bucket
SEAT BACKREST COVER - SECOND ROW, BUCKET
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9750
Exploded View
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9751
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9752
Second Row, 60 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9753
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9754
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9755
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9756
Second Row, Bucket, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9757
Second Row, Bucket, Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9758
Second Row, Bucket, Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9759
Second Row, 60 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9760
Second Row, 60 Percent Bench, Cushion
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9761
Second Row, 40 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9762
Second Row, 40 Percent Bench, Cushion
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 as high as it will go.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9763
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.
40 Percent E-Z Entry
SEAT CUSHION COVER - SECOND ROW, 40 PERCENT E-Z ENTRY
Exploded View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9764
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9765
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9766
Second Row, 60 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9767
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9768
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9769
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9770
Second Row, Bucket, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9771
Second Row, Bucket, Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9772
Second Row, Bucket, Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9773
Second Row, 60 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9774
Second Row, 60 Percent Bench, Cushion
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9775
Second Row, 40 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9776
Second Row, 40 Percent Bench, Cushion
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.
Release the hook-and-loop strips and remove the cushion trim cover from the cushion foam pad.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9777
4. To install, reverse the removal procedure.
60 Percent, E-Z Entry
SEAT CUSHION COVER - SECOND ROW, 60 PERCENT, E-Z ENTRY
Exploded View
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9778
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9779
Second Row, 60 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9780
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9781
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9782
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9783
Second Row, Bucket, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9784
Second Row, Bucket, Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9785
Second Row, Bucket, Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9786
Second Row, 60 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9787
Second Row, 60 Percent Bench, Cushion
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9788
Second Row, 40 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9789
Second Row, 40 Percent Bench, Cushion
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.
Release the hook-and-loop strips and separate the cushion trim cover from the cushion foam pad.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9790
4. To install, reverse the removal procedure.
- After installation, make sure the LATCH and safety belt buckles are accessible to the occupants.
40 Percent, Bench
SEAT CUSHION COVER - SECOND ROW, 40 PERCENT, BENCH
Exploded View
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9791
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9792
Second Row, 60 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9793
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9794
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9795
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9796
Second Row, Bucket, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9797
Second Row, Bucket, Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9798
Second Row, Bucket, Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9799
Second Row, 60 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9800
Second Row, 60 Percent Bench, Cushion
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9801
Second Row, 40 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9802
Second Row, 40 Percent Bench, Cushion
Removal and Installation
1. Remove the second row 40 percent seat of the 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.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9803
60 Percent, Bench
SEAT CUSHION COVER - SECOND ROW, 60 PERCENT, BENCH
Exploded View
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9804
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9805
Second Row, 60 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9806
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9807
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9808
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9809
Second Row, Bucket, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9810
Second Row, Bucket, Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9811
Second Row, Bucket, Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9812
Second Row, 60 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9813
Second Row, 60 Percent Bench, Cushion
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9814
Second Row, 40 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9815
Second Row, 40 Percent Bench, Cushion
Removal and Installation
1. Remove the second row 60 percent seat of the 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.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9816
Bucket
SEAT CUSHION COVER - SECOND ROW, BUCKET
Exploded View
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9817
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9818
Second Row, 60 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9819
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9820
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9821
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9822
Second Row, Bucket, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9823
Second Row, Bucket, Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9824
Second Row, Bucket, Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9825
Second Row, 60 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9826
Second Row, 60 Percent Bench, Cushion
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9827
Second Row, 40 Percent Bench, Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9828
Second Row, 40 Percent Bench, Cushion
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.
2. Release the cable from the seat riser and remove the cushion trim cover.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9829
3. To install, reverse the removal procedure.
Seat Backrest Cover - Third Row
SEAT BACKREST COVER - THIRD ROW
Exploded View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9830
Third Row Seat Backrest
Third Row Seat Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9831
Third Row Seat Cushion (Part 2)
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
Exploded View
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9832
Third Row Seat Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9833
Third Row Seat Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9834
Third Row Seat Cushion (Part 2)
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 9843
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 9849
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 (V8-4.6L (2008))
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
Exploded View
Third Row Seat Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9852
Third Row Seat Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9853
Third Row Seat Cushion (Part 2)
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9854
Seat Cushion: Overhaul
Seat Cushion - Front
SEAT CUSHION - FRONT
Special Tool(s)
Special Tool(s)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9855
Driver Seat Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9856
Driver Seat Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9857
Passenger Seat Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9858
Passenger Seat Cushion (Part 2)
Disassembly and Assembly
WARNING:
- Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive
load limiting retractors. Failure to follow this instruction may result in the accidental deployment of
the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious
personal injury or death.
- Never probe the electrical connectors on air bag, safety canopy or side air curtain modules.
Failure to follow this instruction may result in the accidental deployment of these modules, which
increases the risk of serious personal injury or death.
NOTE:
- The air bag warning indicator 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.
All seats
1. Remove the front seat. 2. Remove the seat track. 3. Remove the front seat backrest.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9859
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. 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.
40 Percent E-Z Entry
SEAT CUSHION - SECOND ROW, 40 PERCENT E-Z ENTRY
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9860
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9861
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9862
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. 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9863
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.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9864
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.
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).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9865
8. Route the outboard recliner short cable, attach the cable to the latch feet assembly outboard foot
and attach the cable casing retainers.
9. Route the outboard recliner long cable, attach it to the kneeling mechanism inboard leg and
attach all cable casing retainers.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9866
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.
- 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.
60 Percent, E-Z Entry
SEAT CUSHION - SECOND ROW, 60 PERCENT, E-Z ENTRY
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9867
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9868
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9869
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. 17. Release the tab and slide the latch feet retracting
link retainer back.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9870
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.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9871
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.
5. Position the recliner release shaft onto the inboard recliner release pivot stub.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9872
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).
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9873
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.
14. Install the outboard recliner long cable to the kneeling mechanism inboard leg and attach all
cable casing retainers.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9874
15. Route the kneeling mechanism release cable, position the kneeling mechanism release cable
pivot at the inboard recliner and attach all cable casing
retainers.
16. Make sure the inboard recliner pin is through the cable pivot.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9875
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.
40 Percent, Bench
SEAT CUSHION - SECOND ROW, 40 PERCENT, BENCH
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9876
Disassembly and Assembly
1. Remove the second row 40 percent seat of the 60/40 bench seat. 2. Remove the second row, 40
percent 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.
4. Remove the cushion foam pad. 5. Remove the cushion pad supports. 6. To assemble, reverse
the disassembly procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9877
60 Percent, Bench
SEAT CUSHION - SECOND ROW, 60 PERCENT, BENCH
Disassembly and Assembly
1. Remove the second row 60 percent seat of the 60/40 bench seat. 2. Remove the second row 60
percent bench seat backrest.
- To install, tighten to 40 Nm (30 lb-ft).
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 J-clips, separate the hook-and-loop fasteners, remove the hog rings and the cushion
trim cover.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9878
5. Remove the cushion foam pad. 6. Remove 2 cushion pad supports. 7. To assemble, reverse the
disassembly procedure.
Bucket
SEAT CUSHION - SECOND ROW, BUCKET
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9879
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9880
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
SEAT CUSHION - THIRD ROW
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9881
Third Row Seat Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9882
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 (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information and Instructions > Page 9887
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9888
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9889
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9890
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9891
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9892
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9893
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9894
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9895
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9896
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9897
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9898
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9899
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9900
Seat Heater: Connector Views
C335
C365
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Information and Instructions > Page 9901
C334
C364
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9902
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 (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams
can be found at Diagrams By Number. See:
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9903
Diagrams/Electrical Diagrams/Diagrams By Number
Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams
can be found at Location Views. See: Locations/Component Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Page
9907
C2347
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair
> Heated Seat Switch > Page 9910
Seat Heater Switch: Service and Repair Seat Control Switch
SEAT CONTROL SWITCH
Exploded View
Front Seat Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair
> Heated Seat Switch > Page 9911
Front Seat Backrest (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair
> Heated Seat Switch > Page 9912
Driver Seat Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair
> Heated Seat Switch > Page 9913
Driver Seat Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair
> Heated Seat Switch > Page 9914
Passenger Seat Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair
> Heated Seat Switch > Page 9915
Passenger Seat Cushion (Part 2)
Special Tool(s)
Special Tool(s)
Removal and Installation
NOTE:
- The air bag warning indicator 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.
All seats
1. Remove the front seat. 2. Remove the cushion side shield in the following sequence.
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. If a passenger seat has been serviced, do not prove out the SRS at this time.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair
> Heated Seat Switch > Page 9916
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair
> Heated Seat Switch > Page 9917
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair
Seat Latch: Service and Repair
SEAT LATCH - THIRD ROW, MANUAL
Exploded View
Third Row Seat Backrest
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Page
9921
Third Row Seat Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Page
9922
Third Row Seat Cushion (Part 2)
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).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Page
9923
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).
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair
Seat Track: Service and Repair
SEAT TRACK
Exploded View
Front Seat Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page
9927
Front Seat Backrest (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page
9928
Driver Seat Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page
9929
Driver Seat Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page
9930
Passenger Seat Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page
9931
Passenger Seat Cushion (Part 2)
Special Tool(s)
Special Tool(s)
Removal and Installation
NOTE:
- The air bag warning indicator 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.
All seats
1. Remove the front seat.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page
9932
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 in the following sequence.
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
7. Disconnect the SRS seat position sensor.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page
9933
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 shown, driver 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. 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page
9934
- 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. 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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Vacuum/Pressure Pump, Seats > Component Information >
Locations
View 151-28
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Seats > Vacuum/Pressure Pump, Seats > Component Information >
Locations > Page 9938
C366
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch >
Component Information > Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch >
Component Information > Locations > Page 9943
C2089
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 151-32
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 9948
View 151-31
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 9951
C605
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Page 9952
Power Door Lock Switch: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Page 9953
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Page 9954
- Release the 4 retaining tabs.
5. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations
View 151-31
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 9958
C527
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 9959
Power Mirror Switch: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 9960
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 9961
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Locations > Third Row Folding Seat Switch
Power Seat Switch: Locations Third Row Folding Seat Switch
View 151-22
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Locations > Third Row Folding Seat Switch > Page 9966
View 151-30
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Locations > Third Row Folding Seat Switch > Page 9967
View 151-22
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Locations > Third Row Folding Seat Switch > Page 9968
View 151-30
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Locations > Third Row Folding Seat Switch > Page 9969
Power Seat Switch: Locations Power Seat Switch
View 151-28
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Locations > Third Row Folding Seat Switch > Page 9970
View 151-29
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Diagrams > Power Seat Switch
Power Seat Switch: Diagrams Power Seat Switch
C352
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Diagrams > Power Seat Switch > Page 9973
C3016
C355
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Diagrams > Power Seat Switch > Page 9974
Power Seat Switch: Diagrams Third Row Folding Seat Switch
C4179
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Diagrams > Power Seat Switch > Page 9975
C4180
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Power Seat Switch, Left - 10-Way Power Seat
Power Seat Switch: Testing and Inspection Power Seat Switch, Left - 10-Way Power Seat
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Power Seat Switch, Left - 10-Way Power Seat > Page 9978
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Power Seat Switch, Left - 10-Way Power Seat > Page 9979
Power Seat Switch: Testing and Inspection Power Seat Switch, Left - 6-Way Power Seat
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Power Seat Switch, Left - 10-Way Power Seat > Page 9980
Power Seat Switch: Testing and Inspection Power Seat Switch, Right
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Page 9981
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock
Switch > Component Information > Locations
View 151-35
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock
Switch > Component Information > Locations > Page 9985
C4039
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Locations > Page 9989
C2347
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Service and Repair > Heated Seat Switch > Page 9992
Seat Heater Switch: Service and Repair Seat Control Switch
SEAT CONTROL SWITCH
Exploded View
Front Seat Backrest (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Service and Repair > Heated Seat Switch > Page 9993
Front Seat Backrest (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Service and Repair > Heated Seat Switch > Page 9994
Driver Seat Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Service and Repair > Heated Seat Switch > Page 9995
Driver Seat Cushion (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Service and Repair > Heated Seat Switch > Page 9996
Passenger Seat Cushion (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Service and Repair > Heated Seat Switch > Page 9997
Passenger Seat Cushion (Part 2)
Special Tool(s)
Special Tool(s)
Removal and Installation
NOTE:
- The air bag warning indicator 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.
All seats
1. Remove the front seat. 2. Remove the cushion side shield in the following sequence.
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. If a passenger seat has been serviced, do not prove out the SRS at this time.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Service and Repair > Heated Seat Switch > Page 9998
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Service and Repair > Heated Seat Switch > Page 9999
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch >
Component Information > Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch >
Component Information > Locations > Page 10003
C2094
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch >
Component Information > Locations
Sunroof / Moonroof Switch: Locations
View 151-36
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch >
Component Information > Locations > Page 10007
View 151-37
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch >
Component Information > Locations > Page 10008
Sunroof / Moonroof Switch: Diagrams
C912
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch >
Component Information > Locations > Page 10009
C9001
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch >
Component Information > Locations > Page 10010
C9038
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch >
Component Information > Testing and Inspection > Roof Opening Panel Switch
Sunroof / Moonroof Switch: Testing and Inspection Roof Opening Panel Switch
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch >
Component Information > Testing and Inspection > Roof Opening Panel Switch > Page 10013
Sunroof / Moonroof Switch: Testing and Inspection Roof Opening Panel Switch With Rear Window
Motor
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch >
Component Information > Testing and Inspection > Roof Opening Panel Switch > Page 10014
Sunroof / Moonroof Switch: Testing and Inspection Roof Opening Panel Switch With Medium
Overhead Console
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch >
Component Information > Testing and Inspection > Page 10015
Sunroof / Moonroof 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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar Switch >
Component Information > Locations
View 151-35
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar Switch >
Component Information > Locations > Page 10019
C479
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and
Operation > Insulation
Sound Proofing / Insulation: Description and Operation Insulation
INSULATION
Insulation is used as a sound-deadener to reduce exterior road and powertrain noises from the
interior of the vehicle. Mastic insulators are also used as insulation. For information on the location
of the mastic insulators, refer to Sound Proofing / Insulation. Insulation is installed:
- under the hood.
- in front of the instrument panel.
- over and under the tunnel.
- over the front and rear floor pans.
- inside the B-, C- and D-pillars.
- on the wheel house/quarter panel.
- on the engine side dash insulator (behind the engine-car rearward).
It has heat-bondable mastic deadeners for improved noise, vibration and harshness (NVH)
characteristics.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and
Operation > Insulation > Page 10024
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 (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and
Operation > Insulation > Page 10025
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 (V8-4.6L (2008))
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
Exploded View
Explorer/Explorer Sport Trac
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and
Repair > Page 10031
Mountaineer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and
Repair > Page 10032
Removal and Installation
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 (V8-4.6L (2008))
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
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component
Information > Service and Repair > Page 10037
Part 2
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 (V8-4.6L (2008))
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
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component
Information > Service and Repair > Page 10041
Part 2
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 (V8-4.6L (2008))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations >
Deactivator Switch
Brake Switch (Cruise Control): Locations Deactivator Switch
View 151-1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations >
Deactivator Switch > Page 10047
View 151-4
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations >
Deactivator Switch > Page 10048
Brake Switch (Cruise Control): Locations Brake Pedal Position Switch
View 151-1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations >
Deactivator Switch > Page 10049
View 151-4
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams >
Deactivator Switch
C277
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams >
Deactivator Switch > Page 10052
C278
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page
10053
Brake Switch (Cruise Control): Description and Operation
Brake Pedal Position (BPP) Switch
Typical BPP Switch
The BPP switch is sometimes referred to as the 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 antilock 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.
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 (V8-4.6L (2008))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page
10054
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Locations > Deactivator Switch
Brake Switch (Cruise Control): Locations Deactivator Switch
View 151-1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Locations > Deactivator Switch > Page 10063
View 151-4
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Locations > Deactivator Switch > Page 10064
Brake Switch (Cruise Control): Locations Brake Pedal Position Switch
View 151-1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Locations > Deactivator Switch > Page 10065
View 151-4
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Diagrams > Deactivator Switch > Page 10068
C278
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Diagrams > Page 10069
Brake Switch (Cruise Control): Description and Operation
Brake Pedal Position (BPP) Switch
Typical BPP Switch
The BPP switch is sometimes referred to as the 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 antilock 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.
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 (V8-4.6L (2008))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Diagrams > Page 10070
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Air Bag Deactivation Indicator > Component
Information > Diagrams
C2286
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Air Bag Deactivation Indicator > Component
Information > Diagrams > Page 10078
Air Bag Deactivation Indicator: Service and Repair
PASSENGER AIR BAG DEACTIVATION (PAD) INDICATOR
Removal and Installation
NOTE:
- The air bag warning indicator 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 SRS. 2. Remove the floor console. 3. Gently pull outward to release the clips on
the instrument panel (I/P) center finish panel. 4. Disconnect the passenger air bag deactivation
(PAD) indicator electrical connector. 5. Remove the 2 screws and PAD indicator. 6. To install,
reverse the removal procedure. 7. Repower the SRS.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10083
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10084
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10085
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10086
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10087
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10088
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10089
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10090
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10091
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10092
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10093
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10094
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10095
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10096
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 (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams
can be found at Diagrams By Number. See:
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 10097
Diagrams/Electrical Diagrams/Diagrams By Number
Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams
can be found at Location Views. See: Locations/Component Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams
C909
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Service and Repair > Vehicle Demagnetizing > Page 10103
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. From the SETUP menu, select compass zone. 3.
Determine which magnetic zone you are in for your geographic location.
4. Press the RESET button until the message center display changes to show the current zone
setting. 5. Press the RESET button repeatedly until the correct zone setting for your geographic
location is displayed. 6. 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.
3. Determine which magnetic zone you are in for your geographic location.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Service and Repair > Vehicle Demagnetizing > Page 10104
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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Service and Repair > Vehicle Demagnetizing > Page 10105
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, heated windshield,
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, heated windshield,
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 (V8-4.6L (2008))
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 eye protection when servicing a vehicle. Failure to follow this instruction may result in
serious personal injury.
- Never probe the electrical connectors on air bag, safety canopy or side air curtain modules.
Failure to follow this instruction may result in the accidental deployment of these modules, which
increases the risk of serious personal injury or death.
- 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 this
instruction may result in the accidental deployment of the safety canopy and cause serious
personal injury or death.
- To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to
follow this instruction may result in serious personal injury or death.
NOTE: The air bag warning indicator 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.
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 warning indicator for at least 30 seconds.
The air bag warning indicator will remain lit
continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning
indicator does not remain lit continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition switch to OFF.
6. WARNING: Always deplete the backup power supply before repairing or installing any new front
or side air bag supplemental restraint
system (SRS) component and before servicing, removing, installing, adjusting or striking
components near the front or side impact sensors or the restraints control module (RCM). Nearby
components include doors, instrument panel, console, door latches, strikers, seats and hood
latches.
Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and
impact sensor(s).
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Failure to follow these instructions may result in serious personal injury or death in the event of an
accidental deployment.
Disconnect the battery ground cable and wait at least one minute.
Repowering Procedure
1. Turn the ignition switch from OFF to ON. 2. Install RCM fuse 17 (10A) to the SJB and close the
cover.
3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of
any air bag module when the battery is
connected. Failure to follow these instructions may result in serious personal injury in the event of
an accidental deployment. Connect the
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 10111
battery ground cable.
Connect the battery ground cable.
4. 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 warning indicator with the air bag modules installed. The air bag
warning indicator will light continuously for approximately 6 seconds and then turn off. If an SRS
fault is present, the air bag warning indicator will: fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag warning 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 warning 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 warning
indicator and any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the RCM and occupant classification system module (OCSM)
using a scan tool.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 10112
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 eye protection when servicing a vehicle. Failure to follow this instruction may result in
serious personal injury.
- Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear
seam pointed away from the body. Do not set a live air bag module down with the deployment
door/trim cover/tear seam face down. Failure to follow these instructions may result in serious
personal injury in the event of an accidental deployment.
- Never probe the electrical connectors on air bag, safety canopy or side air curtain modules.
Failure to follow this instruction may result in the accidental deployment of these modules, which
increases the risk of serious personal injury or death.
- Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive
load limiting retractors. Failure to follow this instruction may result in the accidental deployment of
the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious
personal injury or death.
- 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.
- To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to
follow this instruction may result in serious personal injury or death.
NOTE: The air bag warning indicator 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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 10113
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 warning indicator for at least 30 seconds.
The air bag warning indicator will remain lit
continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning
indicator does not remain lit continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: Always deplete the backup power supply before repairing or installing any new front
or side air bag supplemental restraint
system (SRS) component and before servicing, removing, installing, adjusting or striking
components near the front or side impact sensors or the restraints control module (RCM). Nearby
components include doors, instrument panel, console, door latches, strikers, seats and hood
latches.
Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and
impact sensor(s).
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Failure to follow these instructions may result in serious personal injury or death in the event of an
accidental deployment.
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.
9. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 10114
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.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 10115
15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat
side air bag module electrical connector.
Explorer and Mountaineer vehicles 16. Release and position aside the passenger side C-pillar trim
panel.
17. Disconnect the passenger side safety canopy module electrical connector.
18. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy module electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 10116
19. Release and position aside the driver side C-pillar trim panel.
20. Disconnect the driver side safety canopy module electrical connector.
21. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy module electrical connector.
Explorer Sport Trac vehicles 22. Remove the driver and passenger side upper C-pillar trim panels.
23. Disconnect the passenger side safety canopy module electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 10117
24. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy module electrical connector.
25. Disconnect the driver side safety canopy module electrical connector.
26. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy module electrical connector.
All vehicles 27. 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 10118
28. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air
bag module electrical connector.
29. Install the RCM fuse 17 (10A) to the SJB. 30. 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. 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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 10119
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.
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 10. Remove the restraint system diagnostic tool from the
vehicle harness side of the driver side safety canopy module electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 10120
11. Connect the driver side safety canopy module electrical connector.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 10121
15. Install the passenger side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
All vehicles 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 10122
19. Connect the LH side passenger air bag module electrical connector.
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 driver air bag module electrical connectors are unique and cannot be reversed
when connected to 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. Damage to the connector or component
may occur.
Connect the driver air bag module electrical connectors as noted in removal.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 10123
24. Install the 2 driver air bag module bolts (1 shown).
- Tighten to 7 Nm (62 lb-in).
25. 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.
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: Make sure no one is in the vehicle and there is nothing blocking or placed in front
of any air bag module when the battery is
connected. Failure to follow these instructions may result in serious personal injury in the event of
an accidental deployment.
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 warning indicator with the air bag modules installed. The air bag
warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag
SRS fault is present, the air bag warning indicator will: fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag warning 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 warning 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 warning
indicator and any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the RCM and occupant classification system module (OCSM)
using a scan tool.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information >
Service and Repair
Dimmer Switch: Service and Repair
INSTRUMENT PANEL DIMMER SWITCH
1. Remove the driver side register. 2. Remove the headlamp switch and bezel as an assembly.
- Disconnect the electrical connectors.
3. Release the 2 tabs and remove the instrument panel dimmer switch.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information >
Service and Repair > Page 10127
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Locations > Liftgate Glass Ajar Switch
View 151-35
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Locations > Liftgate Glass Ajar Switch > Page 10132
Door Switch: Locations Door Ajar Switch
View 151-31
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Locations > Liftgate Glass Ajar Switch > Page 10133
View 151-32
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Locations > Liftgate Glass Ajar Switch > Page 10134
View 151-34
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Locations > Liftgate Glass Ajar Switch > Page 10135
View 151-33
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Diagrams > Liftgate Glass Ajar Switch
C478
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Diagrams > Liftgate Glass Ajar Switch > Page 10138
Door Switch: Diagrams Door Ajar Switch
C526
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Diagrams > Liftgate Glass Ajar Switch > Page 10139
C602
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Diagrams > Liftgate Glass Ajar Switch > Page 10140
C715
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Diagrams > Liftgate Glass Ajar Switch > Page 10141
C820
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Service and Repair > Door Ajar Switch - Front Door
Door Switch: Service and Repair Door Ajar Switch - Front Door
DOOR AJAR SWITCH - FRONT DOOR
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Service and Repair > Door Ajar Switch - Front Door > Page 10144
Part 2
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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Service and Repair > Door Ajar Switch - Front Door > Page 10145
Door Switch: Service and Repair Door Ajar Switch - Liftgate
DOOR AJAR SWITCH - LIFTGATE
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Service and Repair > Door Ajar Switch - Front Door > Page 10146
Part 2
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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Service and Repair > Door Ajar Switch - Front Door > Page 10147
Door Switch: Service and Repair Door Ajar Switch - Liftgate Glass
DOOR AJAR SWITCH - LIFTGATE GLASS
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Service and Repair > Door Ajar Switch - Front Door > Page 10148
Part 2
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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Service and Repair > Door Ajar Switch - Front Door > Page 10149
Door Switch: Service and Repair Door Ajar Switch - Rear Door
DOOR AJAR SWITCH - REAR DOOR
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Service and Repair > Door Ajar Switch - Front Door > Page 10150
Part 2
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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Locations
View 151-13
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Locations > Page 10154
C253
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Locations > Page 10155
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 SELECT/RESET button on base instrument
clusters (IC), and by the message center switches on high series instrument clusters (IC). 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 (V8-4.6L (2008))
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. 2. Visually inspect for obvious signs of mechanical or electrical
damage.
Visual Inspection Chart
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
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 (IC).
9. If the DTCs retrieved are related to the concern, go to DTC Charts. For all other DTCs, refer to
Body Control Systems (Multifunction Electronic
Control Module). See: Testing and Inspection/Diagnostic Trouble Code Descriptions/Information
and Message Center
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
NOTE: The smart junction box (SJB) is also known as the generic electronic module (GEM).
The message center information can be selected through the SELECT/RESET button (base
cluster) and by the INFO, SETUP, and RESET buttons (high series cluster).
The message center is an integral part of the instrument cluster (IC) that receives and acts upon
much of the same information that is input and used to operate the instrument cluster (IC) gauges,
informational indicators, and warning indicators. The message center, located in the center of the
instrument cluster (IC) is a liquid crystal display (LCD). The message center electronic functions
use both hardwired and the controller area network (CAN) circuitry to transmit and receive
information.
Whenever conditions are present that require a warning message, the message center replaces
the last selected display with the new warning display. Once the message is reset or cleared, the
message center returns to the last selected display. If multiple warnings are present, the message
center displays each warning for approximately 4 seconds. Warning messages are also generally
associated with other observable instrument cluster (IC) indications. For example, when the LH
front door is opened, the message center displays the message DRIVER DOOR AJAR along with
the door ajar warning
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Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10158
indicator. This allows the message center to be a more informative supplement to the instrument
cluster (IC) gauges and indicators.
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 that received the input (message) controls the output of the feature, or if it outputs a
message over the CAN to another module.
- which module controls the output of the feature.
Instrument Cluster (IC) Network Messages
NOTE: Whenever a network message is suspected as missing, confirmed by a missing message
DTC, it is important to look for other symptoms that may also be present in the instrument cluster
(IC) and throughout the vehicle. Once a DTC is set in the instrument cluster (IC), it may be helpful
to review the complete message list available in Information Bus (Module Communications
Network) to see what other modules also rely on the same message and run the self-test for those
modules. If the message is missing from other modules, the same DTC may also be set in those
modules. Confirmation of missing messages common to multiple modules may indicate that the
originating module is the source of the concern or the communication network may be experiencing
some problems.
The instrument cluster (IC) uses input messages from other modules to control the gauges,
informational indicators, warning indicators and message center displays over the communication
networks. If a required message is missing or invalid for less than 5 seconds, the gauge or
indicator that requires the message remains at the last commanded state based upon the last
known good message. For example, if the message is missing for the driver door ajar off status for
less than 5 seconds and the door ajar indicator was on, the indicator remains in the on state until
the next good message is received. If the message remains missing or invalid for greater than 5
seconds, the instrument cluster (IC) sets a U-code DTC and the output becomes a default action
for the indicator or gauge. Each indicator or gauge utilizes a different default strategy depending on
the nature of the indication. Refer to Instrument Cluster for further descriptions of the default action
specific to each indicator or gauge. If the messaged input to the cluster returns at any time, the
normal function of the gauge or indicator resumes.
Message Center Features
The message center provides the following features: Information displays
- Setup displays
- System check messages
- Warning messages
Information Displays (Base Instrument Cluster [IC])
The information displays are non-timed modes. The selected mode remains on until the driver
presses the SELECT/RESET 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 (if equipped)
- Distance to empty
- Average fuel economy
- Setup menu
Information Displays (High Series Instrument Cluster [IC])
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
- Distance to empty
- Average fuel economy
- Instantaneous fuel economy
- Fuel used
- Trip elapsed drive time
- Blank
Setup Displays (Base Instrument Cluster [IC])
The setup displays are timed modes and terminate after a finite interval. Press the
SELECT/RESET button to scroll through the SETUP MENU display sequence. If the
SELECT/RESET button is not pressed within 4 seconds, the message center returns to the INFO
MENU. The setup display modes are: System check
- Units (English/metric)
- Language
- Autolamp
- Autolock
- Auto-unlock
- Parking aid (if equipped)
- Oil life reset and start value
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10159
Setup Displays (High Series Instrument Cluster [IC])
The setup displays are timed modes and terminate after a finite interval. Press the SETUP button
for the following displays: System check
- Units (English/metric)
- Language
- Autolamp
- Autolock
- Auto-unlock
- Running boards (if equipped)
- Easy entry/exit seat (if equipped)
- Parking aid (if equipped)
- Compass zone
- Compass calibration
- Oil life reset and 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 (IC), the
SELECT/RESET button must be held down after pressing the SELECT/RESET button to cycle the
messages through each of the systems being monitored. For high series instrument clusters (IC),
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
- CHARGING SYSTEM
- WASHER FLUID
- DOOR AJAR
- EXTERIOR LAMPS
- BRAKE FLUID LEVEL
- PARK BRAKE
- FUEL LEVEL AND DISTANCE TO EMPTY (high series instrument cluster [IC])
- MILES TO EMPTY (base instrument cluster [IC])
- FUEL LEVEL LOW (base instrument cluster [IC])
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
The warning messages that reoccur after 10 minutes are: 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 (if equipped)
- 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
- CLEAR OBJECTS BY PASS SEAT
- CHECK CHARGING SYSTEM
- LOW TIRE PRESSURE
- TIRE MONITOR FAULT
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Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10160
- TIRE SENSOR FAULT
The message center displays messages that indicate a system state during the operation of the
four wheel drive (4WD) system. The displayed warning messages are as follows: FOR 4X4 LOW STOP VEHICLE (if equipped)
- FOR 4X4 LOW SHIFT TO N (if equipped)
- TO EXIT 4X4 LOW STOP VEHICLE (if equipped)
- TO EXIT 4X4 LOW SHIFT TO N (if equipped)
The message center displays messages that indicate a system state during repair procedures
related to the tire pressure monitoring system (TPMS). The displayed warning messages are as
follows: TRAIN TIRES
- TIRES TRAINED
- TIRES NOT TRAINED
The message center displays messages that indicate a system state during repair procedures
related to the compass display. The displayed warning messages are as follows: COMPASS ZONE XX (base instrument cluster [IC])
- RESET FOR ZONE SETTING (high series instrument cluster [IC])
- ZONE XX RESET TO CHANGE (high series instrument cluster [IC])
- ZONE XX IS SET
- PRESS RESET FOR CALIBRATION (high series instrument cluster [IC])
- CIRCLE SLOW TO CALIBRATE (base instrument cluster [IC])
- CIRCLE SLOWLY TO CALIBRATE (high series instrument cluster [IC])
- CALIBRATION COMPLETED
The message center displays messages that indicate a system state during repair procedures
related to the oil life and oil life start value. The displayed warning messages are as follows: HOLD RESET IF NEW OIL
- OIL LIFE SET TO 100%
- OIL LIFE START VALUE SET TO XXX% (high series instrument cluster [IC])
- OIL LIFE SET TO XXX% (base instrument cluster [IC])
Outside Air Temperature Sensor (Instrument Cluster [IC] Without Electronic Automatic
Temperature Control [EATC])
The instrument cluster (IC) 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 EATC, the outside air temperature data from the
outside air temperature sensor is displayed in the heating ventilation air conditioning (HVAC)
module. Refer to Heating and Air Conditioning for the outside air temperature display in the EATC.
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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10161
Driver/Vehicle Information Display: Symptom Related Diagnostic Procedures
Symptom Chart (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10162
Symptom Chart (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10163
Symptom Chart (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10164
Symptom Chart (Part 4)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10165
Symptom Chart (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10166
Symptom Chart (Part 6)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10167
Driver/Vehicle Information Display: Pinpoint Tests
Test A: The Message Center Is Not Operating Correctly (High Series Instrument Cluster [IC])
PINPOINT TEST A: THE MESSAGE CENTER IS NOT OPERATING CORRECTLY (HIGH
SERIES INSTRUMENT CLUSTER [IC])
Normal Operation
The message center functionality is controlled through the message center switch, which is
hardwired to the instrument cluster (IC) through circuits CMC29 (GN/VT) and RMC32 (GN/BU).
This pinpoint test is intended to diagnose the following:
- Message center switch concern
- Instrument cluster (IC)
A1
A2
Test B: The Compass Is Inoperative
PINPOINT TEST B: THE COMPASS IS INOPERATIVE
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 (IC), 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 (IC).
- DTC B2097 (Compass Module Failure) - is a continuous memory DTC that sets in the instrument
cluster (IC) if the data received from the compass module is invalid.
- DTC U2013 (Compass Module is Not Responding) - is a continuous and on-demand DTC that
sets if the instrument cluster (IC) fails to receive a response from the compass module after 4
consecutive attempts.
This pinpoint test is intended to diagnose the following:
- Fuse
- Wiring, terminals or connectors
- Compass sensor module
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Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10168
B1
B1-B3
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Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10169
B3-B4
Test C: The Compass Is Inaccurate
PINPOINT TEST C: THE COMPASS IS INACCURATE
Normal Operation
The compass sensor module communicates the vehicle direction to the instrument cluster (IC)
through the compass communication data plus circuit VMC31 (YE/GN) and compass
communication data minus circuit VMC30 (BU/GY). The magnetic fields generated by the earths
north and south poles are divided into zones that differ from each other with respect to how the
magnetic fields appear. The magnetic north can change by up to 4 degrees between zones and
become noticeable across multiple zones. The compass zone must be set to the correct zone for
the compass to read accurately. Factors within the vehicle may affect the ability of the compass
module to accurately read the magnetic north. Calibrating the compass allows the compass module
to compensate for vehicle factors that influence the accuracy of the compass.
This pinpoint test is intended to diagnose the following:
- Calibration
- Zone setting
- Vehicle magnetization
- Compass sensor module
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Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10170
C1-C2
Test D: The Message Center Switch Does Not Operate Correctly (High Series Instrument Cluster
[IC])
PINPOINT TEST D: THE MESSAGE CENTER SWITCH DOES NOT OPERATE CORRECTLY
(HIGH SERIES INSTRUMENT CLUSTER [IC])
Normal Operation
The message center switch uses circuit CMC29 (GN/VT) to communicate the requested switch
function to the instrument cluster (IC) 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 (IC) to determine which switch is pressed.
This pinpoint test is intended to diagnose the following:
- Wiring, terminals or connectors
- Message center switch
- Instrument cluster (IC)
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Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10171
D1-D3
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Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10172
D3-D5
Test E: The Outside Air Temperature Display Does Not Operate Correctly
PINPOINT TEST E: THE OUTSIDE AIR TEMPERATURE DISPLAY DOES NOT OPERATE
CORRECTLY
NOTE: The outside air temperature display is only available in base instrument clusters (IC) without
electronic automatic temperature control (EATC).
Normal Operation
The outside air temperature sensor is mounted on the radiator core support in front of the radiator
and A/C condenser and is hardwired to the instrument cluster (IC) through input circuit VH407
(YE/GN) and return circuit RMC32 (GN/BU). The instrument cluster (IC) provides a reference
voltage to the ambient air temperature sensor and monitors the change in voltage resulting from
changes in resistance as determined by outside air temperature. When the engine has been off for
an extended period of time, or the engine temperature is cold, the instrument cluster (IC) displays
the
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Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10173
current outside air temperature as measured by the ambient air temperature sensor. When the
engine has only been turned off for a short time, or if the engine is not cold, the instrument cluster
(IC) takes a reading of the current temperature and compares the current reading against the last
reading at key off. If the temperature is less than the last key off temperature reading, the
instrument cluster (IC) displays the current temperature. If the temperature is greater than the last
key off temperature reading, the instrument cluster (IC) displays the last key off temperature
reading until the ambient air temperature has had time to stabilize with vehicle movement.
- DTC B1255 (Air Temperature External Sensor Circuit Open) - is a continuous and on-demand
DTC that sets if the instrument cluster (IC) detects an open on the outside air temperature sensor
input circuit VH407 (YE/GN). If the instrument cluster (IC) detects an open on the outside air
temperature input, the instrument cluster (IC) defaults the display to 23.5°Celsius (75°F).
- DTC B1257 (Air Temperature External Sensor Circuit Short to Ground) - is a continuous and
on-demand DTC that sets if the instrument cluster (IC) detects a short to ground on the outside air
temperature sensor input circuit VH407 (YE/GN). If the instrument cluster (IC) detects a short to
ground on the outside air temperature input, the instrument cluster (IC) defaults the display to
23.5°Celsius (75°F).
This pinpoint test is intended to diagnose the following:
- Wiring, terminals or connectors
- Ambient air temperature sensor
- Instrument cluster (IC)
E1-E3
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Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10174
E3-E5
Test F: The WASHER FLUID LOW LEVEL Warning Is Inoperative
PINPOINT TEST F: THE WASHER FLUID LOW LEVEL WARNING IS INOPERATIVE
Normal Operation
The instrument cluster (IC) 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 (IC) through circuit
GD108 (BK/VT) and displaying 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 (IC), and the WASHER FLUID LOW LEVEL warning turns off.
This pinpoint test is intended to diagnose the following:
- Wiring, terminals or connectors
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Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10175
- Washer fluid level switch (part of the windshield washer reservoir)
- Instrument cluster (IC)
F1-F2
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F3-F6
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F6-F7
Test G: The CHECK CHARGING SYSTEM Warning Is Inoperative
PINPOINT TEST G: THE CHECK CHARGING SYSTEM WARNING IS INOPERATIVE
Normal Operation
The charging system warning indicator is controlled by the instrument cluster (IC) based upon data
received from the PCM over the high speed controller area network (HS-CAN).
This pinpoint test is intended to diagnose the following:
- Charging system
- Instrument cluster (IC)
G1-G2
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Component Information > Service and Repair > Message Center Configuration
Driver/Vehicle Information Display: Service and Repair Message Center Configuration
MESSAGE CENTER CONFIGURATION
Oil Life Reset And Start Value - High Series Instrument Cluster
NOTE: The oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180
days.
1. From the setup menu, press and release the RESET button to display HOLD RESET IF NEW
OIL. 2. Press and hold the RESET button for 2 seconds and release to reset the oil life to 100%. 3.
The message center displays OIL LIFE SET TO 100%. 4. Once the message center displays OIL
LIFE SET TO 100%, release the RESET button then press and release the RESET button to
reduce the start
value (10% for each button press).
Oil Life Reset And Start Value - Base Instrument Cluster
NOTE: Oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days.
- All message center functions are carried out using the single stem reset button in the instrument
cluster.
1. Press and release the SELECT/RESET button to scroll through the information displays until the
message center displays HOLD RESET IF NEW
OIL.
2. Press and hold the SELECT/RESET button for approximately 2 seconds until the message
center displays OIL LIFE SET TO 100%. 3. Once OIL LIFE SET TO 100% is displayed, press and
hold the SELECT/RESET button for more than 2 seconds until the message center displays
OIL LIFE SET TO XXX%.
4. Press and release the SELECT/RESET button to reduce the start value (10% for each button
press). 5. Press and release the SELECT/RESET button to exit the procedure.
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Component Information > Service and Repair > Message Center Configuration > Page 10180
Driver/Vehicle Information Display: Service and Repair Message Center Switch
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.
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Special Tool(s)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 10190
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 10196
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 there is a concern in the
EVAP system due to the fuel filler cap or capless fuel tank filler pipe 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 (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions > Page 10204
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions > Page 10205
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions > Page 10206
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions > Page 10207
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions > Page 10208
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions > Page 10209
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions > Page 10210
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions > Page 10211
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions > Page 10212
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions > Page 10213
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions > Page 10214
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions > Page 10215
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions > Page 10216
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Diagrams
Fuel Gauge Sender: Diagrams
C434A
C434B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Diagrams > Page 10220
Fuel Gauge Sender: Description and Operation
Fuel Pump (FP) Module
Typical Electronic Returnless Fuel Pump (FP) Module
Typical Mechanical Returnless Fuel Pump (FP) Module
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Diagrams > Page 10221
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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Diagrams > Page 10222
Fuel Gauge Sender: Service and Repair
FUEL LEVEL SENDER
Removal
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working
on or near any fuel-related component. Highly flammable mixtures are always present and may be
ignited. Failure to follow these instructions may result in serious personal injury.
1. Remove the fuel pump. 2. Remove the screw and the fuel level sender cover.
3. NOTE: Note the routing of the fuel level sender wire for installation.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Diagrams > Page 10223
Remove the heat shrink tube covering the fuel level sender wire electrical connector.
4. Disconnect the fuel level sender wire electrical connector.
5. NOTE: Note the routing of the fuel level sender ground wire for installation.
Disconnect the ground wire and remove the screw and lift up to remove the fuel level sender.
Installation
1. Route the fuel level sender ground wire along the fuel pump body.
2. Route the fuel level sender wire through the center of the fuel pump.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Diagrams > Page 10224
3. NOTE: Both fuel gauge sending wires must be routed behind the metal sending unit plate.
Hook the fuel level sender on the fuel pump and install and tighten the screw. Connect the fuel
level sender unit ground wire.
4. Slide the heat shrink tube onto the wire harness and connect the fuel level sender wire electrical
connector.
5. WARNING: Do not use an open flame to shrink the heat shrink tube. Use a heat gun only. Fuel
residue may be ignited if an open flame is
used. Failure to follow this instruction may result in serious personal injury.
Using a heat gun, shrink the heat shrink tube.
6. Install the fuel level sender cover and screw and tighten the screw. 7. Install the fuel pump.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 eye protection when servicing a vehicle. Failure to follow this instruction may result in
serious personal injury.
- Never probe the electrical connectors on air bag, safety canopy or side air curtain modules.
Failure to follow this instruction may result in the accidental deployment of these modules, which
increases the risk of serious personal injury or death.
- 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 this
instruction may result in the accidental deployment of the safety canopy and cause serious
personal injury or death.
- To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to
follow this instruction may result in serious personal injury or death.
NOTE: The air bag warning indicator 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.
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 warning indicator for at least 30 seconds.
The air bag warning indicator will remain lit
continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning
indicator does not remain lit continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition switch to OFF.
6. WARNING: Always deplete the backup power supply before repairing or installing any new front
or side air bag supplemental restraint
system (SRS) component and before servicing, removing, installing, adjusting or striking
components near the front or side impact sensors or the restraints control module (RCM). Nearby
components include doors, instrument panel, console, door latches, strikers, seats and hood
latches.
Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and
impact sensor(s).
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Failure to follow these instructions may result in serious personal injury or death in the event of an
accidental deployment.
Disconnect the battery ground cable and wait at least one minute.
Repowering Procedure
1. Turn the ignition switch from OFF to ON. 2. Install RCM fuse 17 (10A) to the SJB and close the
cover.
3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of
any air bag module when the battery is
connected. Failure to follow these instructions may result in serious personal injury in the event of
an accidental deployment. Connect the
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 10230
battery ground cable.
Connect the battery ground cable.
4. 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 warning indicator with the air bag modules installed. The air bag
warning indicator will light continuously for approximately 6 seconds and then turn off. If an SRS
fault is present, the air bag warning indicator will: fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag warning 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 warning 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 warning
indicator and any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the RCM and occupant classification system module (OCSM)
using a scan tool.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 10231
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 eye protection when servicing a vehicle. Failure to follow this instruction may result in
serious personal injury.
- Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear
seam pointed away from the body. Do not set a live air bag module down with the deployment
door/trim cover/tear seam face down. Failure to follow these instructions may result in serious
personal injury in the event of an accidental deployment.
- Never probe the electrical connectors on air bag, safety canopy or side air curtain modules.
Failure to follow this instruction may result in the accidental deployment of these modules, which
increases the risk of serious personal injury or death.
- Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive
load limiting retractors. Failure to follow this instruction may result in the accidental deployment of
the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious
personal injury or death.
- 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.
- To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to
follow this instruction may result in serious personal injury or death.
NOTE: The air bag warning indicator 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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 10232
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 warning indicator for at least 30 seconds.
The air bag warning indicator will remain lit
continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning
indicator does not remain lit continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: Always deplete the backup power supply before repairing or installing any new front
or side air bag supplemental restraint
system (SRS) component and before servicing, removing, installing, adjusting or striking
components near the front or side impact sensors or the restraints control module (RCM). Nearby
components include doors, instrument panel, console, door latches, strikers, seats and hood
latches.
Refer to the Description and Operation portion of Air Bag Systems for location of the RCM and
impact sensor(s).
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Failure to follow these instructions may result in serious personal injury or death in the event of an
accidental deployment.
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.
9. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 10233
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.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 10234
15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat
side air bag module electrical connector.
Explorer and Mountaineer vehicles 16. Release and position aside the passenger side C-pillar trim
panel.
17. Disconnect the passenger side safety canopy module electrical connector.
18. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy module electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 10235
19. Release and position aside the driver side C-pillar trim panel.
20. Disconnect the driver side safety canopy module electrical connector.
21. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy module electrical connector.
Explorer Sport Trac vehicles 22. Remove the driver and passenger side upper C-pillar trim panels.
23. Disconnect the passenger side safety canopy module electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 10236
24. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy module electrical connector.
25. Disconnect the driver side safety canopy module electrical connector.
26. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy module electrical connector.
All vehicles 27. 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 10237
28. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air
bag module electrical connector.
29. Install the RCM fuse 17 (10A) to the SJB. 30. 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. 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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 10238
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.
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 10. Remove the restraint system diagnostic tool from the
vehicle harness side of the driver side safety canopy module electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 10239
11. Connect the driver side safety canopy module electrical connector.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 10240
15. Install the passenger side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
All vehicles 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 10241
19. Connect the LH side passenger air bag module electrical connector.
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 driver air bag module electrical connectors are unique and cannot be reversed
when connected to 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. Damage to the connector or component
may occur.
Connect the driver air bag module electrical connectors as noted in removal.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 10242
24. Install the 2 driver air bag module bolts (1 shown).
- Tighten to 7 Nm (62 lb-in).
25. 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.
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: Make sure no one is in the vehicle and there is nothing blocking or placed in front
of any air bag module when the battery is
connected. Failure to follow these instructions may result in serious personal injury in the event of
an accidental deployment.
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 warning indicator with the air bag modules installed. The air bag
warning indicator will light continuously for approximately 6 seconds and then turn off. If an air bag
SRS fault is present, the air bag warning indicator will: fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag warning 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 warning 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 warning
indicator and any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the RCM and occupant classification system module (OCSM)
using a scan tool.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Removal and Installation
1. Remove the instrument cluster (IC).
2. NOTE: To remove the illumination bulb, rotate the bulb one quarter turn counterclockwise and lift
out from the IC.
Remove the illumination bulb(s).
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Bulb > Component Information > Service and Repair > Instrument Cluster Bulb > Page 10247
Instrument Panel Bulb: Service and Repair Warning Indicator Bulb
WARNING INDICATOR BULB
Removal and Installation
1. Remove the instrument cluster (IC).
2. NOTE: To remove a warning indicator bulb, rotate the bulb one quarter turn counterclockwise
and lift it out from the instrument cluster (IC).
Remove the warning indicator bulb(s) in question.
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-21-7 > Nov > 09 >
Instruments - Trip Odometers/Fuel Economy Resets > Page 10256
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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: > 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 (V8-4.6L (2008))
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: > 09-21-7 >
Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 10262
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument
Panel Control Module: > 09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle
Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0196/RPM
Loss/Slow Idle
TSB 09-22-6
11/16/09
4.6L ENGINE -CHECK ENGINE LIGHT ON - DTC P0196 - COLD WEATHER DRIVING
CONDITIONS- CALIBRATION UPDATE
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
ISSUE Some 2006-2008 Explorer, Mountaineer and Sport Trac vehicles and equipped with 4.6L
3-V engines may exhibit:
^ Diagnostic trouble code (DTC) P0196 - engine oil temperature (EOT) sensor range/performance
during ice/snow driving conditions.
^ Idle speed dropping below specification, hesitation or loss of RPM with no DTCs stored in the
Powertrain Control Module (PCM).
^ Cruise control surge at approximately 50-60 MPH (80-97 Km/h) in hilly regions Only applies to
vehicles operated in altitudes above 5000 feet (1.52
km).
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
If normal Powertrain Controls/Emissions Diagnosis (PC/ED) diagnostics do not resolve the above
vehicle concerns, reprogram the PCM and Transmission Control Module (1CM) to the latest
calibration using IDS release 63.08 and higher. This new calibration is not included in the VCM
2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
VEHICLES EQUIPPED WITH A PCM AND TCM, REQUIRE A COORDINATED
REPROGRAMMING.
THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE FOLLOWED EXACTLY AS
OUTLINED BY THE INTERGRATED DIAGNOSTIC SYSTEM (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 63.08 and higher. This new calibration
is not included in the VCM 2009.9 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:
(1) Choose all Tests and Calibrations.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument
Panel Control Module: > 09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle > Page 10268
(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
DISCONNECTING 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 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. Brake gently to a complete
stop and hold foot on brake for at least 10 seconds.
g. Repeat Steps (e-f) a total of three (3) 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
092206A 2006-2008 Explorer, 1.0 Hr.
Mountaineer 2007-2008 Explorer Sport Trac: Check DTCs, Reprogram The PCM And TCM
Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor
Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument
Panel Control Module: > 09-22-6 > Nov > 09 > Engine Controls - MIL ON/DTC P0196/RPM Loss/Slow Idle > Page 10274
(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
DISCONNECTING 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 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. Brake gently to a complete
stop and hold foot on brake for at least 10 seconds.
g. Repeat Steps (e-f) a total of three (3) 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
092206A 2006-2008 Explorer, 1.0 Hr.
Mountaineer 2007-2008 Explorer Sport Trac: Check DTCs, Reprogram The PCM And TCM
Includes Time To Clear KAM And Perform Road Tests (Do Not Use With Any Other Labor
Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Tire Pressure Monitoring System (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.
Tire Pressure Monitoring System (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.
NOTE: For vehicles with different front and rear tire pressures (such as E-Series and certain
F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the
sensors will result in a false low tire pressure event, which will cause the TPMS indicator to
illuminate.
1. The TPMS indicator remains on continuously for the following 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 the Tire Pressure Monitoring
System (TPMS) Sensor Activation procedure.
Tire Pressure Monitoring System (TPMS) Indicator Flashes
The TPMS indicator flashes for 70 seconds, then remains ON solid when the ignition switch is
turned to the ON position, for the following conditions: 1. Tire Pressure Sensor Fault - If equipped,
the message center will display TIRE PRESSURE 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 not received
any signals from the SJB for more than 5 seconds. If equipped, the message center displays TIRE
PRESSURE 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 PRESSURE
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 (V8-4.6L (2008))
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
MESSAGE CENTER CONFIGURATION
Oil Life Reset And Start Value - High Series Instrument Cluster
NOTE: The oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180
days.
1. From the setup menu, press and release the RESET button to display HOLD RESET IF NEW
OIL. 2. Press and hold the RESET button for 2 seconds and release to reset the oil life to 100%. 3.
The message center displays OIL LIFE SET TO 100%. 4. Once the message center displays OIL
LIFE SET TO 100%, release the RESET button then press and release the RESET button to
reduce the start
value (10% for each button press).
Oil Life Reset And Start Value - Base Instrument Cluster
NOTE: Oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days.
- All message center functions are carried out using the single stem reset button in the instrument
cluster.
1. Press and release the SELECT/RESET button to scroll through the information displays until the
message center displays HOLD RESET IF NEW
OIL.
2. Press and hold the SELECT/RESET button for approximately 2 seconds until the message
center displays OIL LIFE SET TO 100%. 3. Once OIL LIFE SET TO 100% is displayed, press and
hold the SELECT/RESET button for more than 2 seconds until the message center displays
OIL LIFE SET TO XXX%.
4. Press and release the SELECT/RESET button to reduce the start value (10% for each button
press). 5. Press and release the SELECT/RESET button to exit the procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > Customer Interest: > 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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > Customer Interest: > 10-2-15 > Feb > 10 > Instruments - Odometer Display Moves On Screen
> Page 10292
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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > Customer Interest: > 10-2-15 > Feb > 10 > Instruments - Odometer Display Moves On Screen
> Page 10293
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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > Customer Interest: > 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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > Customer Interest: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy
Resets > Page 10298
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > All Technical Service Bulletins: > 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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > All Technical Service Bulletins: > 10-2-15 > Feb > 10 > Instruments - Odometer Display Moves
On Screen > Page 10304
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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > All Technical Service Bulletins: > 10-2-15 > Feb > 10 > Instruments - Odometer Display Moves
On Screen > Page 10305
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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > All Technical Service Bulletins: > 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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > All Technical Service Bulletins: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel
Economy Resets > Page 10310
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Odometer: > 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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Odometer: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th
Gears/Ratio DTC's Set > Page 10316
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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Odometer: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th
Gears/Ratio DTC's Set > Page 10317
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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Odometer: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th
Gears/Ratio DTC's Set > Page 10318
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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Odometer: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th
Gears/Ratio DTC's Set > Page 10319
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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Odometer: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th
Gears/Ratio DTC's Set > Page 10325
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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Odometer: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th
Gears/Ratio DTC's Set > Page 10326
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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Odometer: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th
Gears/Ratio DTC's Set > Page 10327
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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Odometer: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th
Gears/Ratio DTC's Set > Page 10328
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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Locations
Oil Pressure Sender: Locations
View 151-1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Locations > Page 10332
View 151-9
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Locations > Page 10333
C103
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component
Information > Description and Operation
Outside Temperature Display: Description and Operation
EXTERNAL TEMPERATURE DISPLAY
The external temperature is displayed when the EXT button is pressed. While the actual external
temperature can vary continuously, the value that is displayed will update at a specific rate
depending on whether or not the engine is "hot" and whether or not the vehicle is moving.
When the external temperature is rising, the display will update slowly.
Updates (when the actual external temperature is higher than currently displayed value) will be
limited to 0.6°C (1°F) every 20 seconds while the vehicle is moving at greater than 40 kph (25 mph)
for more than 90 seconds OR 0.6°C (1°F) every 20 minutes if the vehicle is not moving at this
speed. This is to prevent the heat from the engine compartment from affecting the accuracy of the
display.
When the external temperature is dropping, the display will update quickly.
Updates (when the actual external temperature is lower than currently displayed value) will only be
limited to 0.6°C (1°F) every 2 seconds (regardless of vehicle speed). Consequently the display will
essentially follow the drop experienced by the external temperature thermistor.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator >
Component Information > Diagrams
Parking Assist Warning Indicator: Diagrams
C3268
C4015
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch >
Component Information > Locations
Parking Brake Warning Switch: Locations
View 151-18
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch >
Component Information > Locations > Page 10343
View 151-19
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch >
Component Information > Locations > Page 10344
C2015
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 10354
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 10360
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 10369
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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
10375
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component
Information > Description and Operation
Seat Belt Reminder Buzzer: 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(R)
The Belt-Minder(R) 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 indicator in
the instrument cluster.
To activate or deactivate the Belt-Minder(R) feature, refer to Instrument Panel, Gauges and
Warning Indicators or the Owner's Literature.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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(R)
The Belt-Minder(R) 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 indicator in
the instrument cluster.
To activate or deactivate the Belt-Minder(R) feature, refer to Instrument Panel, Gauges and
Warning Indicators or the Owner's Literature.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Dimmer Switch > Component Information > Service and Repair
Dimmer Switch: Service and Repair
INSTRUMENT PANEL DIMMER SWITCH
1. Remove the driver side register. 2. Remove the headlamp switch and bezel as an assembly.
- Disconnect the electrical connectors.
3. Release the 2 tabs and remove the instrument panel dimmer switch.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Dimmer Switch > Component Information > Service and Repair > Page 10386
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch
View 151-35
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch > Page 10391
Door Switch: Locations Door Ajar Switch
View 151-31
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch > Page 10392
View 151-32
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch > Page 10393
View 151-34
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Locations > Liftgate Glass Ajar Switch > Page 10394
View 151-33
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch
C478
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 10397
Door Switch: Diagrams Door Ajar Switch
C526
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 10398
C602
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 10399
C715
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 10400
C820
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door
Door Switch: Service and Repair Door Ajar Switch - Front Door
DOOR AJAR SWITCH - FRONT DOOR
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 10403
Part 2
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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 10404
Door Switch: Service and Repair Door Ajar Switch - Liftgate
DOOR AJAR SWITCH - LIFTGATE
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 10405
Part 2
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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 10406
Door Switch: Service and Repair Door Ajar Switch - Liftgate Glass
DOOR AJAR SWITCH - LIFTGATE GLASS
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 10407
Part 2
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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 10408
Door Switch: Service and Repair Door Ajar Switch - Rear Door
DOOR AJAR SWITCH - REAR DOOR
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 10409
Part 2
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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Diagrams
Fuel Gauge Sender: Diagrams
C434A
C434B
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Diagrams > Page 10413
Fuel Gauge Sender: Description and Operation
Fuel Pump (FP) Module
Typical Electronic Returnless Fuel Pump (FP) Module
Typical Mechanical Returnless Fuel Pump (FP) Module
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Diagrams > Page 10414
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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Diagrams > Page 10415
Fuel Gauge Sender: Service and Repair
FUEL LEVEL SENDER
Removal
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working
on or near any fuel-related component. Highly flammable mixtures are always present and may be
ignited. Failure to follow these instructions may result in serious personal injury.
1. Remove the fuel pump. 2. Remove the screw and the fuel level sender cover.
3. NOTE: Note the routing of the fuel level sender wire for installation.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Diagrams > Page 10416
Remove the heat shrink tube covering the fuel level sender wire electrical connector.
4. Disconnect the fuel level sender wire electrical connector.
5. NOTE: Note the routing of the fuel level sender ground wire for installation.
Disconnect the ground wire and remove the screw and lift up to remove the fuel level sender.
Installation
1. Route the fuel level sender ground wire along the fuel pump body.
2. Route the fuel level sender wire through the center of the fuel pump.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Diagrams > Page 10417
3. NOTE: Both fuel gauge sending wires must be routed behind the metal sending unit plate.
Hook the fuel level sender on the fuel pump and install and tighten the screw. Connect the fuel
level sender unit ground wire.
4. Slide the heat shrink tube onto the wire harness and connect the fuel level sender wire electrical
connector.
5. WARNING: Do not use an open flame to shrink the heat shrink tube. Use a heat gun only. Fuel
residue may be ignited if an open flame is
used. Failure to follow this instruction may result in serious personal injury.
Using a heat gun, shrink the heat shrink tube.
6. Install the fuel level sender cover and screw and tighten the screw. 7. Install the fuel pump.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Parking Brake Warning Switch > Component Information > Locations
Parking Brake Warning Switch: Locations
View 151-18
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Parking Brake Warning Switch > Component Information > Locations > Page 10421
View 151-19
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Parking Brake Warning Switch > Component Information > Locations > Page 10422
C2015
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Tire Pressure Monitoring System (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.
Tire Pressure Monitoring System (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.
NOTE: For vehicles with different front and rear tire pressures (such as E-Series and certain
F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the
sensors will result in a false low tire pressure event, which will cause the TPMS indicator to
illuminate.
1. The TPMS indicator remains on continuously for the following 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 the Tire Pressure Monitoring
System (TPMS) Sensor Activation procedure.
Tire Pressure Monitoring System (TPMS) Indicator Flashes
The TPMS indicator flashes for 70 seconds, then remains ON solid when the ignition switch is
turned to the ON position, for the following conditions: 1. Tire Pressure Sensor Fault - If equipped,
the message center will display TIRE PRESSURE 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 not received
any signals from the SJB for more than 5 seconds. If equipped, the message center displays TIRE
PRESSURE 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 PRESSURE
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 (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure
Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training
Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor
Training
Tire Pressure Monitoring System (TPMS) Sensor Training
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). For additional information, refer to
Tire Pressure Monitoring System (TPMS) Sensor Activation.
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 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 activation tool, attempt to activate the same sensor with
the activation tool. If the sensor still does not respond, move the vehicle to rotate the wheels at
least 1/4 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. NOTE: 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.
6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the
activation tool must remain in place 180 degrees from
the valve stem.
Place the activation tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press
and release the test button on the special tool. The horn will sound briefly to indicate that the tire
pressure sensor has been recognized by the SJB.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure
Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training >
Page 10431
7. Within 2 minutes of the horn sounding, place the 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.
8. 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.
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 IDs trained to the SJB and document them
on the applicable warranty claim.
10. 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.
If the sensors are being trained due to the installation of a new SJB, clear any DTCs and perform
the SJB on-demand self test.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure
Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training >
Page 10432
Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor
Activation
Tire Pressure Monitoring System (TPMS) Sensor Activation
NOTE: The tire pressure sensors will go into a "sleep mode" after 30 minutes of inactivity to
conserve battery power. The sensors do not transmit information while in sleep mode, it will be
necessary to wake them up so they will transmit the latest tire pressure information.
1. Turn the ignition switch to the ON position. 2. Position the tire pressure monitor activation tool
against the LF tire sidewall 180 degrees from the tire valve stem.
3. NOTE: The activation tool will provide feedback in the form of a flashing green light and a beep
sound for each successful response from a tire
pressure sensor.
Press the test button on the activation tool to activate the sensor, activate the sensor at least 2
times.
4. Repeat Steps 2 and 3 for the remaining tires. 5. If the tire pressure monitoring system (TPMS)
indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom
Chart
in Diagnosis and Testing.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Disassembly
WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous
chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes,
flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any
part of the battery is swallowed, contact a physician immediately. When disposing of TPMS
sensors, follow the correct procedures for hazardous material disposal. Failure to follow these
instructions may result in serious personal injury.
NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of
accordingly.
NOTE: 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.
1. CAUTION: The sensor, cradle and strap may 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 may occur.
Using a pocket screwdriver or similar tool, remove the sensor locking clip.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 10435
3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to
the sensor may 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 may 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 (V8-4.6L (2008))
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 10436
3. CAUTION: The sensor, cradle and strap may 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 (V8-4.6L (2008))
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 10437
Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and
Cradle
Tire Pressure Monitoring System (TPMS) Strap and Cradle
Disassembly
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 10438
WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous
chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes,
flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any
part of the battery is swallowed, contact a physician immediately. When disposing of TPMS
sensors, follow the correct procedures for hazardous material disposal. Failure to follow these
instructions may result in serious personal injury.
NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of
accordingly.
NOTE: 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.
1. Remove the tire pressure monitoring system (TPMS) sensor. For additional information, refer to
Tire Pressure Monitoring System (TPMS) Sensor.
2. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this
instruction may result in serious personal injury.
WARNING: Wear protective gloves when handling components or parts that have pointed or sharp
edges. Failure to follow this instruction may result in serious personal injury.
Remove a factory installed strap in the following 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.
3. To remove a dealer installed strap, turn the worm gear screw until the strap is fully released from
the worm gear.
^ Discard the strap.
4. 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 may 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 (V8-4.6L (2008))
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 10439
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 degrees 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 and
sensor are mounted at the lowest spot
possible to avoid damaging the sensor during wheel and tire disassembly and assembly.
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 lb-inch).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 10440
6. CAUTION: The sensor, cradle and strap may 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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations
View 151-13
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 10448
C286
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 10449
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 (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Locations
Backup Lamp Switch: Locations
View 151-7
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Locations > Page 10454
View 151-11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Locations > Page 10455
C167
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10460
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10461
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10462
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10463
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10464
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10465
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10466
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10467
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10468
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10469
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10470
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10471
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10472
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10473
Brake Lamp: Connector Views
C4032
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10474
C4034
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10475
C4035
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10476
C4036
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10477
C418
C419
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10478
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.
90-3
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10479
90-4
Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, 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 Location Views. See: Locations/Component Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
INSPECTION AND VERIFICATION
1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical or electrical
damage.
Visual Inspection Chart
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
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 DTC Charts. 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
NOTE: The smart junction box (SJB) is also known as the generic electronic module (GEM).
The SJB monitors the input from the stoplamp switch. When the brake pedal is applied, voltage is
routed to the SJB. The SJB then supplies voltage to the stoplamps.
Field-Effect Transistor (FET) Protection
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Inspection and Diagnostic Overview > Page 10482
The SJB utilizes a FET protective circuit strategy for many of its outputs (for example, the
headlamp output circuit). Output loads (current level) are monitored for excessive current (typically
short circuits) and are shut down (turns off the voltage or ground provided by the module) when a
fault is detected. A continuous DTC is stored at the time of the fault. The circuit then resets after a
customer demand of the function (switching the component on, battery saver being energized).
When an excessive circuit load occurs several times, the module shuts down the output until a
repair procedure is carried out. At the same time, the continuous DTC that was stored on the first
failure cannot be cleared by a command to clear the continuous DTCs. The module does not allow
this code to be cleared or the circuit restored to normal until a successful on-demand self-test
proves that the fault has been repaired. After the on-demand self-test has successfully completed
(no on-demand DTCs present), the continuous DTC clears and the circuit function returns.
Each circuit has 3 predefined levels of short circuit tolerance established in the module based on
each circuits' capability. When the first or second level is reached, the continuous DTC associated
with the circuit sets along with DTC B106E. These DTCs may be cleared using the Clear DTC
operation on the scan tool as long as the fault itself has been corrected. If any of the circuits are
shorted past the third level, then B106F and B1342 set along with the associated continuous DTC.
These DTCs cannot be cleared and the module must be replaced.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Inspection and Diagnostic Overview > Page 10483
Brake Lamp: Diagnostic Trouble Code Descriptions
B2048-B2049
B2050-B2051 / C1446-C1788
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Inspection and Diagnostic Overview > Page 10484
Symptom Chart
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Inspection and Diagnostic Overview > Page 10485
Brake Lamp: Pinpoint Tests
Test H: All The Stoplamps Are Inoperative
PINPOINT TEST H: ALL THE STOPLAMPS ARE INOPERATIVE
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) which then supplies voltage to all the stoplamps.
This pinpoint test is intended to diagnose the following:
- Fuse
- Wiring, terminals or connectors
- Stoplamp switch
- SJB
H1-H2
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Inspection and Diagnostic Overview > Page 10486
H3-H5
Test I: One Or More Stoplamps Are Inoperative
PINPOINT TEST I: ONE OR MORE STOPLAMPS ARE INOPERATIVE
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).
Explorer
When the SJB detects the brake pedal is 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).
Explorer Sport Trac
When the SJB detects the brake pedal is 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).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Inspection and Diagnostic Overview > Page 10487
Mountaineer
When the SJB detects the brake pedal is 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).
This pinpoint test is intended to diagnose the following:
- Fuse
- Wiring, terminals or connectors
- High mounted stoplamp
- LED module
- SJB
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Inspection and Diagnostic Overview > Page 10488
I1-I6
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Inspection and Diagnostic Overview > Page 10489
I6-I8
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Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10490
I8-I10
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Inspection and Diagnostic Overview > Page 10491
I10-I12
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10492
I12-I13
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Inspection and Diagnostic Overview > Page 10493
I14-I15
Test J: The Stoplamps Are On Continuously
PINPOINT TEST J: THE STOPLAMPS ARE ON CONTINUOUSLY
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 brake control (TBC) module, the 4X4 control
module, the ABS module, and the 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).
Explorer, Explorer Sport Trac
When the SJB detects the brake pedal is applied, the SJB provides voltage to the LH and RH rear
stoplamps through circuits CLS18 (GY/BN) and CLS19 (VT/OG), respectively.
Mountaineer
When the SJB detects the brake pedal is applied, the SJB provides voltage to the LH and RH rear
stoplamps through circuit CLS44 (VT/BN).
- DTC B1446 (Brake Switch Circuit Failure) - is an on-demand DTC that sets when the SJB detects
a short to voltage from the brake pedal applied input circuit.
- DTC B2049 (Left Rear Turn Lamp Circuit Open) - is a continuous and on-demand DTC that sets
when the SJB detects a short to voltage from the LH rear turn lamp voltage supply circuit.
- DTC B2051 (Right Rear Turn Lamp Circuit Open) - is a continuous and on-demand DTC that sets
when the SJB detects an open from the RH rear turn lamp voltage supply circuit.
This pinpoint test is intended to diagnose the following:
- Wiring, terminals or connectors
- Stoplamp switch
- Trailer brake control (TBC) module
- Brake shift interlock actuator
- 4X4 control module
- ABS module
- PCM
- SJB
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Inspection and Diagnostic Overview > Page 10494
J1-J8
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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Inspection and Diagnostic Overview > Page 10495
J9-J13
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Inspection and Diagnostic Overview > Page 10496
J14
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10497
Special Tool(s)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations
Brake Light Switch: Locations
View 151-1
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View 151-4
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C278
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Brake Light Switch: Description and Operation
BRAKE PEDAL POSITION (BPP) SWITCH
Typical BPP Switch
The BPP switch is sometimes referred to as the 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 antilock 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.
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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 (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Cargo Lamp
C926
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Ford Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Cargo Lamp > Page
10509
C927
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Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams
C475
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Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams
C254
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
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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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
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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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
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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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
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Symbols (Part 2)
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Information and Instructions > Page 10525
Symbols (Part 3)
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Information and Instructions > Page 10526
Symbols (Part 4)
Symbols (Part 5)
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Information and Instructions > Page 10527
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 terminal by pulling each wire at the end of the connector.
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Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
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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
3 = Splice tape
4 = Harness tape
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Information and Instructions > Page 10530
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.
3. lnstall 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 seat wire splice.
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Information and Instructions > Page 10531
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.
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 6.35mm (1/4 in) 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.
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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.
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, barrel squeeze tool handles appropriate 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.
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The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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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
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97-2
Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, 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 Location Views. See: Locations/Component Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection
> Initial Inspection and Diagnostic Overview
Daytime Running Lamp: Initial Inspection and Diagnostic Overview
Inspection and Verification
INSPECTION AND VERIFICATION
1. Verify the customer concern. 2. 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 not in the HIGH BEAM position.
3. 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).
4. 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.
5. 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
PCM.
6. 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.
7. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related
Diagnostic Procedures
Principles of Operation
PRINCIPLES OF OPERATION
NOTE: The smart junction box (SJB) is also known as the generic electronic module (GEM).
The DRL feature operates the low beam headlamps at a reduced intensity when the ignition switch
is in the RUN position, the headlamps are not on from any other input, and the transmission is not
in PARK (P).
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 (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection
> Initial Inspection and Diagnostic Overview > Page 10538
Symptom Chart
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection
> Initial Inspection and Diagnostic Overview > Page 10539
Daytime Running Lamp: Pinpoint Tests
PINPOINT TEST AE: THE DAYTIME RUNNING LAMPS (DRL) ARE INOPERATIVE
Normal Operation
When the ignition switch is in the RUN position, the headlamps are not on (from the autolamp
system or manual control from the headlamp switch) and the transmission is not in PARK (P), the
smart junction box (SJB) provides a pulse-width modulated (PWM) voltage to the low beam
headlamps. This illuminates the headlamps at a reduced intensity.
This pinpoint test is intended to diagnose the following:
- Exterior lighting system input/output
- Ignition switch input
- Transmission gear input
- SJB
AE1-AE4
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection
> Page 10540
Daytime Running Lamp: Adjustments
AUTOLAMPS TIME DELAY ADJUSTMENT
NOTE: Steps 2 through 5 must be carried out within a 10-second period.
1. Start with the ignition switch OFF position and the headlamp switch in the AUTOLAMPS ON
position. 2. Place the headlamp switch in the OFF position. 3. Place the ignition switch in the RUN
position. 4. Place the ignition switch in the OFF position. 5. Place the headlamp switch in the
AUTOLAMPS ON position. The exterior lamps turn on at this point. 6. Wait the desired amount of
time and place the headlamp switch in the OFF position (maximum of 3 minutes). The exterior
lamps turn off and the
autolamp time delay is now set.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection
> Page 10541
Special Tool(s)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Service and Repair
Dimmer Switch: Service and Repair
INSTRUMENT PANEL DIMMER SWITCH
1. Remove the driver side register. 2. Remove the headlamp switch and bezel as an assembly.
- Disconnect the electrical connectors.
3. Release the 2 tabs and remove the instrument panel dimmer switch.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Service and Repair > Page
10545
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Interior
Lamp - Front > Page 10550
Dome Lamp: Service and Repair Interior Lamp - Rear
INTERIOR LAMP - REAR
Removal and Installation
1. Remove the rear interior lamp lens.
2. Release the 2 retaining clips (through the access holes) and remove the rear interior lamp
assembly.
- Disconnect the electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Interior
Lamp - Front > Page 10551
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Glass Ajar
Switch
View 151-35
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Glass Ajar
Switch > Page 10556
Door Switch: Locations Door Ajar Switch
View 151-31
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Glass Ajar
Switch > Page 10557
View 151-32
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Glass Ajar
Switch > Page 10558
View 151-34
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Liftgate Glass Ajar
Switch > Page 10559
View 151-33
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar
Switch
C478
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar
Switch > Page 10562
Door Switch: Diagrams Door Ajar Switch
C526
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar
Switch > Page 10563
C602
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar
Switch > Page 10564
C715
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar
Switch > Page 10565
C820
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar
Switch - Front Door
Door Switch: Service and Repair Door Ajar Switch - Front Door
DOOR AJAR SWITCH - FRONT DOOR
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar
Switch - Front Door > Page 10568
Part 2
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 (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar
Switch - Front Door > Page 10569
Door Switch: Service and Repair Door Ajar Switch - Liftgate
DOOR AJAR SWITCH - LIFTGATE
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar
Switch - Front Door > Page 10570
Part 2
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 (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar
Switch - Front Door > Page 10571
Door Switch: Service and Repair Door Ajar Switch - Liftgate Glass
DOOR AJAR SWITCH - LIFTGATE GLASS
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar
Switch - Front Door > Page 10572
Part 2
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 (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar
Switch - Front Door > Page 10573
Door Switch: Service and Repair Door Ajar Switch - Rear Door
DOOR AJAR SWITCH - REAR DOOR
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar
Switch - Front Door > Page 10574
Part 2
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 (V8-4.6L (2008))
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
Base Fog Lamp Bulb
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information >
Service and Repair > Page 10579
Adrenalin Package Fog Lamp Bulb
Removal and Installation
WARNING: The 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.
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
Vehicles with base fog lamp
2. NOTE: To remove, rotate the bulb approximately one-eighth turn counter clockwise.
Disconnect the electrical connector and remove the fog lamp bulb.
Vehicles with Adrenalin fog lamp
3. NOTE: To remove, squeeze the tabs and pull the fog lamp bulb from the fog lamp assembly.
Disconnect the electrical connector and remove the fog lamp bulb.
All vehicles
4. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Locations > Page 10583
Fog/Driving Lamp Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and
Repair > Page 10592
Mountaineer
Removal and Installation
WARNING: The 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 (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Locations > Illumination Dimmer Switch
View 151-13
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Locations > Illumination Dimmer Switch > Page 10597
Headlamp Dimmer Switch: Locations Multifunction Switch
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Locations > Illumination Dimmer Switch > Page 10598
View 151-15
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Diagrams > Multifunction Switch
C202
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Diagrams > Multifunction Switch > Page 10601
C2298
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing
and Inspection > Multifunction Switch
Headlamp Dimmer Switch: Testing and Inspection Multifunction Switch
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing
and Inspection > Multifunction Switch > Page 10604
Headlamp Dimmer Switch: Testing and Inspection Illumination Dimmer Switch
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing
and Inspection > Multifunction Switch > Page 10605
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing
and Inspection > Page 10606
Headlamp Dimmer Switch: Service and Repair
Steering Column Multifunction Switch
NOTE: Steering wheel removed for clarity.
Steering Column Multifunction Switch (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing
and Inspection > Page 10607
Steering Column Multifunction Switch (Part 2)
Removal and Installation
CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or
damage to the column may result.
1. Disconnect the battery ground cable. 2. Remove the 2 screws and the steering column opening
cover. 3. Remove the 3 screws and the upper and lower steering column shrouds. 4. Disconnect
the multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the
multi-function switch.
^ To install, tighten to 3 Nm (27 lb-inch).
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations
View 151-13
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations >
Page 10611
C205
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations >
Page 10612
Headlamp Switch: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations >
Page 10613
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations >
Page 10614
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 (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations
View 151-16
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10623
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10624
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10625
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10626
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10627
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10628
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10629
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10630
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10631
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10632
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10633
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10634
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10635
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10636
License Plate Lamp: Connector Views
C452
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10637
C454
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10638
C462
C464
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10639
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.
92-1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 10640
92-3
Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, 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 Location Views. See: Locations/Component Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10645
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10646
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10647
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10648
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10649
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10650
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10651
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10652
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10653
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10654
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10655
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10656
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10657
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10658
Marker Lamp: Connector Views
C1127
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10659
C1126
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10660
C481
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10661
C482
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10662
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.
92-1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10663
92-3
Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, 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 Location Views. See: Locations/Component Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Page 10664
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 (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information > Service
and Repair
Parking Light Bulb: Service and Repair
PARKING LAMP BULB - FRONT
Explorer, Explorer Sport Trac
Mountaineer
Removal and Installation
1. Remove the headlamp assembly. 2. Remove the parking lamp bulb socket from the headlamp
assembly.
- Remove the parking lamp bulb from the socket.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information > Service
and Repair > Page 10672
3. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations > Page 10677
Fog/Driving Lamp Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Locations > Page 10684
Trailer Lighting Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Locations
View 151-13
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Locations > Page 10689
C286
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Locations > Page 10690
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 (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations
Backup Lamp Switch: Locations
View 151-7
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations > Page 10694
View 151-11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations > Page 10695
C167
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations
Brake Light Switch: Locations
View 151-1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 10699
View 151-4
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 10700
C278
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 10701
Brake Light Switch: Description and Operation
BRAKE PEDAL POSITION (BPP) SWITCH
Typical BPP Switch
The BPP switch is sometimes referred to as the 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 antilock 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 (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 10702
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 (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Locations > Liftgate Glass Ajar Switch
View 151-35
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Locations > Liftgate Glass Ajar Switch > Page 10707
Door Switch: Locations Door Ajar Switch
View 151-31
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Locations > Liftgate Glass Ajar Switch > Page 10708
View 151-32
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Locations > Liftgate Glass Ajar Switch > Page 10709
View 151-34
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Locations > Liftgate Glass Ajar Switch > Page 10710
View 151-33
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Diagrams > Liftgate Glass Ajar Switch
C478
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Diagrams > Liftgate Glass Ajar Switch > Page 10713
Door Switch: Diagrams Door Ajar Switch
C526
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Diagrams > Liftgate Glass Ajar Switch > Page 10714
C602
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Diagrams > Liftgate Glass Ajar Switch > Page 10715
C715
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Diagrams > Liftgate Glass Ajar Switch > Page 10716
C820
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Service and Repair > Door Ajar Switch - Front Door
Door Switch: Service and Repair Door Ajar Switch - Front Door
DOOR AJAR SWITCH - FRONT DOOR
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Service and Repair > Door Ajar Switch - Front Door > Page 10719
Part 2
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 (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Service and Repair > Door Ajar Switch - Front Door > Page 10720
Door Switch: Service and Repair Door Ajar Switch - Liftgate
DOOR AJAR SWITCH - LIFTGATE
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Service and Repair > Door Ajar Switch - Front Door > Page 10721
Part 2
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 (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Service and Repair > Door Ajar Switch - Front Door > Page 10722
Door Switch: Service and Repair Door Ajar Switch - Liftgate Glass
DOOR AJAR SWITCH - LIFTGATE GLASS
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Service and Repair > Door Ajar Switch - Front Door > Page 10723
Part 2
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 (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Service and Repair > Door Ajar Switch - Front Door > Page 10724
Door Switch: Service and Repair Door Ajar Switch - Rear Door
DOOR AJAR SWITCH - REAR DOOR
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Service and Repair > Door Ajar Switch - Front Door > Page 10725
Part 2
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 (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Locations > Illumination Dimmer Switch
View 151-13
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Locations > Illumination Dimmer Switch > Page 10730
Headlamp Dimmer Switch: Locations Multifunction Switch
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Locations > Illumination Dimmer Switch > Page 10731
View 151-15
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Diagrams > Multifunction Switch > Page 10734
C2298
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Testing and Inspection > Multifunction Switch
Headlamp Dimmer Switch: Testing and Inspection Multifunction Switch
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Testing and Inspection > Multifunction Switch > Page 10737
Headlamp Dimmer Switch: Testing and Inspection Illumination Dimmer Switch
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Testing and Inspection > Multifunction Switch > Page 10738
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Testing and Inspection > Page 10739
Headlamp Dimmer Switch: Service and Repair
Steering Column Multifunction Switch
NOTE: Steering wheel removed for clarity.
Steering Column Multifunction Switch (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Testing and Inspection > Page 10740
Steering Column Multifunction Switch (Part 2)
Removal and Installation
CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or
damage to the column may result.
1. Disconnect the battery ground cable. 2. Remove the 2 screws and the steering column opening
cover. 3. Remove the 3 screws and the upper and lower steering column shrouds. 4. Disconnect
the multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the
multi-function switch.
^ To install, tighten to 3 Nm (27 lb-inch).
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations
View 151-13
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Page 10744
C205
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Page 10745
Headlamp Switch: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Page 10746
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Page 10747
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 (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component
Information > Locations
View 151-16
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations
Turn Signal Switch: Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 10754
View 151-15
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 10755
C202
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 10756
Turn Signal Switch: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 10757
Turn Signal Switch: Service and Repair
Steering Column Multifunction Switch
NOTE: Steering wheel removed for clarity.
Steering Column Multifunction Switch (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 10758
Steering Column Multifunction Switch (Part 2)
Removal and Installation
CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or
damage to the column may result.
1. Disconnect the battery ground cable. 2. Remove the 2 screws and the steering column opening
cover. 3. Remove the 3 screws and the upper and lower steering column shrouds. 4. Disconnect
the multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the
multi-function switch.
^ To install, tighten to 3 Nm (27 lb-inch).
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10763
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10764
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10765
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10766
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10767
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10768
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10769
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10770
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10771
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10772
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10773
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10774
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10775
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10776
Tail Lamp: Connector Views
C418
C419
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10777
C4032
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10778
C4034
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10779
C4035
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10780
C4036
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10781
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.
92-1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10782
92-3
Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, 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 Location Views. See: Locations/Component Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10787
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10788
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10789
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10790
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10791
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10792
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10793
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10794
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10795
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10796
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10797
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10798
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10799
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10800
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 (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10801
95-2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10802
95-4
Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, 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 Location Views. See: Locations/Component Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Principles of Operation
PRINCIPLES OF OPERATION
NOTE: The smart junction box (SJB) is also known as the generic electronic module (GEM).
The SJB uses existing inputs to determine if voltage needs to be supplied to the individual trailer
stop/turn lamps. The SJB has separate drivers that provide voltage for the trailer turn lamps. The
trailer parking and reversing lamps share the vehicle lighting outputs.
The vehicle is supplied with wiring to support an aftermarket trailer brake control (TBC) module.
The trailer tow battery charging is controlled by a relay. When the ignition switch is in the RUN or
ACC position, the trailer tow battery charge relay is energized, which routes voltage to the trailer
tow connector.
Field-Effect Transistor (FET) Protection
The SJB utilizes a FET protective circuit strategy for many of its outputs (for example, the
headlamp output circuit). Output loads (current level) are monitored for excessive current (typically
short circuits) and are shut down (turns off the voltage or ground provided by the module) when a
fault is detected. A continuous DTC is stored at the time of the fault. The circuit then resets after a
customer demand of the function (switching the component on, battery saver being energized).
When an excessive circuit load occurs several times, the module shuts down the output until a
repair procedure is carried out. At the same time, the continuous DTC that was stored on the first
failure cannot be cleared by a command to clear the continuous DTCs. The module does not allow
this code to be cleared or the circuit restored to normal until a successful on-demand self-test
proves that the fault has been repaired. After the on-demand self-test has successfully completed
(no on-demand DTCs present), the continuous DTC clears and the circuit function returns.
Each circuit has 3 predefined levels of short circuit tolerance established in the module based on
each circuits' capability. When the first or second level is reached, the continuous DTC associated
with the circuit sets along with DTC B106E. These DTCs may be cleared using the Clear DTC
operation on the scan tool as long as the fault itself has been corrected. If any of the circuits are
shorted past the third level, then B106F and B1342 set along with the associated continuous DTC.
These DTCs cannot be cleared and the module must be replaced.
The SJB FET protected output circuits for the trailer lamp system are the LH and RH trailer
stop/turn output circuits.
Inspection and Verification
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 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 (TBC) 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)
- Circuity
- Trailer
- SJB
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).
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10805
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
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 DTC Charts. 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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10806
B2070
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10807
Trailer Lamps: Symptom Related Diagnostic Procedures
Symptom Chart (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10808
Symptom Chart (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10809
Trailer Lamps: Pinpoint Tests
Test W: All The Trailer Lamps Are Inoperative
PINPOINT TEST W: ALL THE TRAILER LAMPS ARE INOPERATIVE
Normal Operation
Ground for the all trailer lamps is provided through circuit RAT08 (WH).
This pinpoint test is intended to diagnose the following:
- Wiring, terminals or connectors
- Trailer tow connector
- Trailer
W1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10810
W1-W2
Test X: The Trailer Lamps Are Inoperative - Parking Lamps
PINPOINT TEST X: THE TRAILER LAMPS ARE INOPERATIVE - PARKING
Normal Operation
When the vehicle parking lamps are on, the smart junction box (SJB) provides voltage to the trailer
parking lamps through circuit CAT17 (BN).
This pinpoint test is intended to diagnose the following:
- Fuse
- Wiring, terminals or connectors
- Trailer tow connector
- Trailer
- SJB
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10811
X1-X2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10812
X2-X4
Test Y: The Trailer Lamps Are Inoperative - Reversing Lamps
PINPOINT TEST Y: THE TRAILER LAMPS ARE INOPERATIVE - REVERSING LAMPS
Normal Operation
Voltage to the trailer reversing lamps is supplied by the smart junction box (SJB) through circuit
CAT16 (GY/BN).
This pinpoint test is intended to diagnose the following:
- Fuse
- Wiring, terminals or connectors
- Trailer tow connector
- Trailer
- SJB
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10813
Y1-Y3
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10814
Y3-Y4
Test Z: The Individual Trailer Lamp Is Inoperative - LH Stop/Turn Lamp
PINPOINT TEST Z: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - LH STOP/TURN LAMP
Normal Operation
Voltage to the LH trailer stop/turn lamp is supplied by the smart junction box (SJB) through circuit
CAT06 (YE).
- DTC B2070 (Trailer Tow Relay Coil(s) Circuit Failure) - is a continuous DTC that sets when the
SJB detects a short to ground from the LH trailer stop/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 trailer stop/turn
lamp voltage supply. A trailer equipped with too many LH stop/turn bulbs may also set the DTC.
This pinpoint test is intended to diagnose the following:
- Trailer equipped with too many bulbs
- Wiring, terminals or connectors
- Trailer tow connector
- Trailer
- SJB
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10815
Z1-Z6
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10816
Z6-Z7
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10817
Z8-Z9
Tests AA: The Individual Trailer Lamp Is Inoperative - RH Stop/Turn Lamp
PINPOINT TEST AA: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - RH STOP/TURN
LAMP
Normal Operation
Voltage to the RH trailer stop/turn lamp is supplied by the smart junction box (SJB) through circuit
CAT09 (GN).
- DTC B2070 (Trailer Tow Relay Coil(s) Circuit Failure) - is a continuous DTC that sets when the
SJB detects a short to ground from the RH trailer stop/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 trailer stop/turn
lamp voltage supply. A trailer equipped with too many RH stop/turn bulbs may also set the DTC.
This pinpoint test is intended to diagnose the following:
- Trailer equipped with too many bulbs
- Wiring, terminals or connectors
- Trailer tow connector
- Trailer
- SJB
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10818
AA1-AA6
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10819
AA6-AA7
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10820
AA8-AA9
Tests AB: The Trailer Lamps Are On Continuously
PINPOINT TEST AB: THE TRAILER LAMPS ARE ON CONTINUOUSLY
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.
The trailer tow parking lamps share the same voltage supply with the vehicle parking lamps.
This pinpoint test is intended to diagnose the following:
- Wiring, terminals or connectors
- Trailer
- SJB
AB1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10821
AB1-AB3
Tests AC: The Trailer Battery Charging Is Inoperative/Does Not Operate Correctly
PINPOINT TEST AC: THE TRAILER BATTERY CHARGING IS INOPERATIVE/DOES NOT
OPERATE CORRECTLY
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 switch 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).
This pinpoint test is intended to diagnose the following:
- Fuse
- Wiring, terminals or connectors
- Trailer battery charge relay
- Trailer tow connector
- Trailer
- SJB
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10822
AC1-AC3
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10823
AC3-AC4
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10824
AC5-AC6
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10825
AC6 Continued
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10826
AC7-AC9
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10827
AC9-AC11
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10828
AC11-AC12
Tests AD: The Trailer Electric Brakes Are Inoperative/Do Not Operate Correctly
PINPOINT TEST AD: THE TRAILER ELECTRIC BRAKES ARE INOPERATIVE/DO NOT
OPERATE CORRECTLY
Normal Operation
The trailer brake control (TBC) module is provided voltage at all times by the battery junction box
(BJB) fuse 17 (30A) through circuit SBB17 (RD). Ground for the TBC module is provided through
circuit GD138 (BK/WH). The TBC module receives voltage from the stoplamp switch through circuit
CCB08 (VT/WH) when the brake pedal is applied. When requested, the TBC module provides
voltage to the trailer tow connector through circuit CAT19 (BU).
This pinpoint test is intended to diagnose the following:
- Fuse
- Wiring, terminals or connectors
- TBC module
- Trailer tow connector
- Trailer
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10829
AD1-AD3
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10830
AD3-AD5
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10831
AD6-AD8
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10832
AD8-AD9
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Page
10833
Special Tool(s)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 10837
Trailer Lighting Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Turn Lamp
Turn Signal Lamp: Diagrams Turn Lamp
C413
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Turn Lamp > Page 10846
C416
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Turn Lamp > Page 10847
Turn Signal Lamp: Diagrams Park/Turn Lamp
C1023
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Turn Lamp > Page 10848
C1115
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Turn Lamp > Page 10849
C1043
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Turn Lamp > Page 10850
C1116
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Turn Lamp > Page 10851
Turn Signal Lamp: Diagrams Park/Stop/Turn Lamp
C4032
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Turn Lamp > Page 10852
C4034
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Turn Lamp > Page 10853
C4035
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Turn Lamp > Page 10854
C4036
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Turn Lamp > Page 10855
Turn Signal Lamp: Diagrams Repeater Lamp
C1108
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Turn Lamp > Page 10856
C1109
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations
Turn Signal Switch: Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations >
Page 10860
View 151-15
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations >
Page 10861
C202
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations >
Page 10862
Turn Signal Switch: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations >
Page 10863
Turn Signal Switch: Service and Repair
Steering Column Multifunction Switch
NOTE: Steering wheel removed for clarity.
Steering Column Multifunction Switch (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations >
Page 10864
Steering Column Multifunction Switch (Part 2)
Removal and Installation
CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or
damage to the column may result.
1. Disconnect the battery ground cable. 2. Remove the 2 screws and the steering column opening
cover. 3. Remove the 3 screws and the upper and lower steering column shrouds. 4. Disconnect
the multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the
multi-function switch.
^ To install, tighten to 3 Nm (27 lb-inch).
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Vanity Mirror Lamp,
Left
C907
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Vanity Mirror Lamp,
Left > Page 10869
C906
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Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component
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Heated Glass Element Relay: Testing and Inspection Rear Window Defrost Relay
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Heated Glass Element Relay: Testing and Inspection Heated Windshield Relay, Left
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Heated Glass Element Relay: Testing and Inspection Heated Windshield Relay, Right
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Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component
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> Component Information > Locations > Rear Window Defrost Relay
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Heated Glass Element Relay: Testing and Inspection Rear Window Defrost Relay
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Heated Glass Element Relay: Testing and Inspection Heated Windshield Relay, Left
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Heated Glass Element Relay: Testing and Inspection Heated Windshield Relay, Right
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Power Window Switch: Locations Window Adjust Switch
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Power Window Switch: Diagrams Master Window Adjust Switch
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Power Window Switch: Diagrams Window Adjust Switch
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Component Information > Testing and Inspection > Master Window Adjust Switch
Power Window Switch: Testing and Inspection Master Window Adjust Switch
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Component Information > Testing and Inspection > Master Window Adjust Switch > Page 10925
Power Window Switch: Testing and Inspection Window Adjust Switches - Passenger Side and
Rear Doors
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Power Window Switch: Testing and Inspection Rear Window Adjust Switch
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Component Information > Testing and Inspection > Page 10927
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.
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Back Window Motor > Component
Information > Testing and Inspection
Back Window Motor: Testing and Inspection
WINDOW MOTOR INITIALIZATION - REAR
WARNING: Keep objects and body parts clear of the glass panel when carrying out the initialization
procedure. During the initialization procedure, the glass panel closes with high force and cannot
detect objects in its path. Failure to follow this instruction may result in serious personal injury.
NOTE:
- The rear window motor is in error mode when shipped and will be inoperative until initialized.
- This procedure must be carried out when repairs are performed on any part of the power rear
window system including when: the power rear window motor is removed from the window
regulator drum housing, a new power rear motor is installed, a new power rear window regulator is
installed, a new power rear window glass module is installed, and any operation in which grease or
lubricants are applied to the power rear window system.
- All power rear window components (window glass module, window regulator, window motor and
glass runs) must be installed and tightened to specification before carrying out this procedure.
1. Open the driver door. 2. Turn the ignition to the ON position. 3. Cycle the ignition OFF and then
back to ON position 5 times. 4. With the ignition still in the ON position, depress and hold the power
rear window control switch in the down position until the rear widow stalls
in the fully open position. Release the control switch.
5. Depress and hold the power rear window control switch in the up position until the rear window
stalls in the fully closed position. Release the
control switch.
6. Verify correct operation of the power rear window by moving the window to the VENT, fully
OPEN and fully CLOSED positions. If the window
does not operate correctly, carefully repeat this procedure.
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Back Window Motor: Service and Repair
WINDOW REGULATOR MOTOR - REAR
Exploded View
Removal and Installation
NOTE: The rear window regulator motor must be initialized when repairs are performed on any part
of the power rear window system including when: the power rear window motor is removed from
the window regulator drum housing, a new power rear motor is installed, a new power rear window
regulator is installed, a new power rear window glass module is installed, and any operation in
which grease or lubricants are applied to the power rear window system.
1. Remove the rear window glass regulator. 2. Remove the 3 window regulator motor bolts.
- To install, tighten to 4 Nm (35 lb-in).
3. Remove the window regulator motor. 4. To install, reverse the removal procedure.
- Initialize the rear window regulator motor. For additional information, refer to Window Motor
Initialization - Rear. See: Testing and Inspection
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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
Exploded View
Part 1
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Component Information > Service and Repair > Page 10937
Part 2
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.
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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
Exploded View
Part 1
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Component Information > Service and Repair > Page 10941
Part 2
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.
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Power Window Switch: Locations Window Adjust Switch
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> Rear Window Adjust Switch
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> Rear Window Adjust Switch > Page 10952
Power Window Switch: Diagrams Master Window Adjust Switch
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Power Window Switch: Diagrams Window Adjust Switch
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C701
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C801
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
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Power Window Switch: Testing and Inspection Master Window Adjust Switch
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Power Window Switch: Testing and Inspection Window Adjust Switches - Passenger Side and
Rear Doors
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Power Window Switch: Testing and Inspection Rear Window Adjust Switch
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Page 10961
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.
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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
Material
Material
Removal
NOTE: If the rear window glass is being removed to repair a dust/water leak, remove and reinstall
the existing rear window glass.
1. Remove the cab rear panel. 2. Remove the 15 rear window glass mounting nuts.
3. CAUTION: Use only a plastic windshield setting tool to slide under the seal to separate the foam
core butyl from the glass. Once the glass
starts to separate from the body, constant hand pressure will break the seal and the glass can be
removed. Failure to use a plastic windshield setting tool can damage the body or the glass frame.
Remove the rear window glass.
Installation
1. NOTE: Remove as much as possible of the foam core butyl from the body and rear window
glass prior to installation.
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Install the rear window glass. Apply foam core butyl to the window. Overlap the foam core butyl by 25 mm (0.984 in) at the
bottom middle of the rear window glass.
- Carefully install the rear window glass into the body opening.
2. Install the 15 rear window glass mounting nuts.
- Tighten to 3 Nm (27 lb-in).
- Test the rear window glass for water leaks.
3. Install the cab rear panel.
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Back Window Glass: Service and Repair Window Glass - Rear, Power
WINDOW GLASS - REAR, POWER
Material
Material
Removal
NOTE: -
The rear window regulator motor must be initialized when repairs are performed on any part of the
power rear window system including when: the power rear window motor is removed from the
window regulator drum housing, a new power rear motor is installed, a new power rear window
regulator is installed, a new power rear window glass module is installed, and any operation in
which grease or lubricants are applied to the power rear window system.
- If the rear window glass is being removed to repair a dust/water leak, remove and reinstall the
existing rear window glass.
1. Remove the rear window glass regulator. 2. Remove both C-pillar upper trim panels. 3. Remove
the 12 rear window glass mounting nuts.
4. CAUTION: Use only a plastic windshield setting tool to slide under the seal to separate the foam
core butyl from the glass. Once the glass
starts to separate from the body, constant hand pressure will break the seal and the glass can be
removed. Failure to use a plastic windshield setting tool can damage the body or the glass frame.
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Information > Service and Repair > Window Glass - Rear, Fixed > Page 10969
Remove the rear window glass.
Installation
1. NOTE: Remove as much as possible of the foam core butyl from the body and rear window
glass prior to installation.
Install the rear window glass. Apply foam core butyl to the window. Overlap the foam core butyl by 25 mm (0.984 in) at the
bottom middle of the rear window glass.
- Carefully install the rear window glass into the body opening.
2. Install the 12 rear window glass mounting nuts.
- Tighten to 3 Nm (27 lb-in).
- Test the rear window glass for water leaks.
3. Install both C-pillar upper trim panels. 4. Install the rear window glass regulator.
- Initialize the rear window regulator motor. For additional information, refer to Window Motor
Initialization - Rear. See: Power Window Motor/Back Window Motor/Testing and Inspection
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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
Exploded View
Part 1
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Window Glass Weatherstrip > Component Information > Service and Repair > Page 10974
Part 2
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.
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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. NOTE: Open and support the liftgate window glass before removing the liftgate window glass
struts.
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Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component
Information > Service and Repair > Page 10978
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.
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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
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Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component
Information > Service and Repair > Page 10982
Removal
1. Remove the rear quarter trim panel. 2. Remove the wiring harness brackets. 3. Before cutting
the urethane adhesive, remove dirt and other foreign material from the windshield pinch weld area.
- Use a clean shop towel or oil-free compressed air.
4. NOTE: Refer to manufacturer's instructions before using the special tool.
Lubricate the urethane adhesive with water to aid the Interior Auto Glass Cut-Out Knife Kit when
cutting the urethane adhesive.
5. 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.
6. WARNING:
- Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result
in serious personal injury.
- Wear protective gloves when handling components or parts that have pointed or sharp edges.
Failure to follow this instruction may result in serious personal injury.
CAUTION: To avoid rust formation, use extreme care not to scratch the paint or primer or
otherwise damage the pinch weld during glass removal.
NOTE: Insert the blade into the special tool so that the flat side is against the glass. This will leave the
entire urethane adhesive bead on the pinch weld and allow a dry fit of the replacement glass.
- Support the glass to prevent the glass from dropping while cutting the urethane adhesive.
Insert the special tool at the upper center of the quarter window glass and work toward the bottom
corners.
7. Insert the Interior Auto Glass Cut-Out Knife Kit into the bottom of the remaining urethane
adhesive and cut from corner to corner. Carefully
remove the quarter glass from the vehicle and place on a stable work surface.
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Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component
Information > Service and Repair > Page 10983
Installation
1. Dry fit the rear quarter window glass in the window opening.
- Position the quarter window glass on the pinch weld.
- Center the quarter glass in the opening for best fit.
- Make alignment marks with tape or non-staining grease pencil on the quarter window glass and
the body.
2. After the dry-fit alignment, remove the glass from the opening and place on a stable work
surface with the interior side of the glass facing upward.
3. WARNING: Repair any corrosion found on the pinch weld. The pinch weld is a structural
component of the vehicle. Corrosion left
unrepaired may reduce the structural integrity of the vehicle. Failure to follow this instruction may
result in serious injury to vehicle occupant(s).
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 1-2 mm (0.04-0.08 in) base of
original equipment urethane on the pinch weld.
4. Using a clean shop towel, brush or oil-free compressed air, clean the pinch weld area around the
existing urethane. Remove any foreign material or
water that may have entered during glass removal.
5. If reinstalling the same quarter window glass, remove the remaining urethane adhesive from the
glass leaving a thin layer to bond with the new
urethane bead.
6. Clean the inside of the new quarter window glass with glass cleaner.
- Make sure to thoroughly clean the surface of the blackened border area where the urethane
adhesive will be applied.
7. NOTE:
- 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.
- 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.
8. Cut the urethane adhesive applicator tip to specification.
9. NOTE:
- Use either a high-ratio, electric or battery-operated caulk gun that will apply the urethane with less
effort and continuous bead.
- The quarter glass must be positioned within 10 minutes of applying the urethane adhesive.
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. Make sure that all gaps in the urethane bead are smoothed into one continuous bead.
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Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component
Information > Service and Repair > Page 10984
10. WARNING: Do not drive vehicle until the urethane seal has cured. Follow urethane
manufacturer's curing directions. Inadequate or
incorrect curing of the urethane seal will adversely affect glass retention. Failure to follow these
instructions may result in serious injury to vehicle occupant(s).
CAUTION: Before positioning the quarter window glass, open vehicle windows to prevent the air
pressure of closing doors from affecting the adhesive bond.
Using the alignment marks made previously, position the quarter window glass on the pinch weld.
11. NOTE: The urethane adhesive must cure for a minimum of one hour before testing for air and
water leaks.
After the urethane adhesive has cured, check for water leaks and add urethane adhesive where
needed.
12. Install the wiring harness brackets. 13. Install the rear quarter trim panel. 14. Clean the exterior
and interior of the quarter window glass with glass cleaner.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door
Window Glass Weatherstrip > Component Information > Service and Repair > Page 10989
Part 2
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 (V8-4.6L (2008))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Back Window Regulator > Component
Information > Service and Repair
Back Window Regulator: Service and Repair
WINDOW REGULATOR - REAR
Exploded View
Removal and Installation
NOTE: The rear window regulator motor must be initialized when repairs are performed on any part
of the power rear window system including when: the power rear window motor is removed from
the window regulator drum housing, a new power rear motor is installed, a new power rear window
regulator is installed, a new power rear window glass module is installed, and any operation in
which grease or lubricants are applied to the power rear window system.
1. Remove the cab rear panel. 2. Position the insulator aside. 3. Remove the 8 window regulator
cover bolts.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Back Window Regulator > Component
Information > Service and Repair > Page 10994
- To install, tighten to 10 Nm (89 lb-in).
4. Remove the window regulator cover-to-motor bolt.
- To install, tighten to 10 Nm (89 lb-in).
5. Remove the window regulator cover. 6. Remove the 2 window regulator mounting nuts.
- To install, tighten to 10 Nm (89 lb-in).
7. Remove the 2 window regulator-to-window bolts.
- To install, tighten to 11 Nm (8 lb-ft).
8. Disconnect the electrical connector. 9. Remove the window regulator.
10. To install, reverse the removal procedure.
- Initialize the rear window regulator motor. For additional information, refer to Window Motor
Initialization - Rear. See: Power Window Motor/Back Window Motor/Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System
Information > Service and Repair > Page 10998
Part 2
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. Damage to the window
regulator will occur 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.
10. Secure the front door glass in the full UP position with tape.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System
Information > Service and Repair > Page 10999
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 (V8-4.6L (2008))
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
Exploded View
Part 1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System
Information > Service and Repair > Page 11003
Part 2
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. Damage to the window
regulator will occur 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 rear window
regulator mounting 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 (V8-4.6L (2008))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures
Windshield: Procedures
GLASS RESEAL - WINDSHIELD
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 cowl panel grille. 7.
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.
8. Cut the urethane applicator tip to specification.
9. NOTE:
- Use either a high-ratio electric or battery-operated caulk gun that will apply the urethane with less
effort and a continuous bead.
- Make sure that all gaps in the urethane adhesive are smoothed into one continuous bead.
Apply a bead of urethane adhesive over the top of the existing urethane adhesive. Apply the urethane adhesive to the top and sides of the windshield glass from the interior of the
vehicle.
- Apply the urethane adhesive to the bottom of the windshield glass from the exterior of the vehicle.
10. NOTE: 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.
11. Install the cowl panel grille. 12. Raise the front portion of the headliner. 13. Install the interior
mirror. 14. Install the sun visors, retainers and, if equipped, the overhead console. 15. If equipped,
install the roof opening panel trim. 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 (V8-4.6L (2008))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures
> Page 11008
Windshield: Removal and Replacement
WINDSHIELD GLASS
Special Tool(s)
Special Tool(s)
Material
Material
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures
> Page 11009
Removal
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 cowl panel grille.
7. 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.
8. NOTE: LH shown, RH similar.
Lower the setting blocks. Use a flat screwdriver to release the setting block and lower.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures
> Page 11010
9. Before cutting the urethane adhesive, remove dirt and other foreign material from the windshield
pinch weld area.
- Use a clean shop towel or oil-free compressed air.
10. NOTE: Refer to manufacturer's instructions before using the special tool.
Lubricate the urethane adhesive with water to aid the Interior Auto Glass Cut-Out Knife Kit when
cutting the urethane adhesive.
11. WARNING:
- Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result
in serious personal injury.
- Wear protective gloves when handling components or parts that have pointed or sharp edges.
Failure to follow this instruction may result in serious personal injury.
CAUTION: To avoid rust formation, use extreme care not to scratch the paint or primer or
otherwise damage the pinch weld during glass removal.
NOTE: Insert the blade into the special tool so that the flat side is against the glass. This will leave the
entire urethane adhesive bead on the pinch weld and allow a dry fit of the replacement windshield
glass.
- Support the windshield glass to prevent the glass from dropping while cutting the urethane
adhesive.
Insert the special tool at the upper center of the windshield glass and work toward the bottom
corners.
12. Using the special tool, distance the windshield from the body.
13. Insert the Interior Auto Glass Cut-Out Knife Kit into the bottom of the remaining urethane
adhesive and cut from corner to corner.
14. NOTE:
- Removing the windshield glass requires more than one technician.
- If reinstalling the windshield glass, tape the windshield at the windshield stops to aid in alignment
of the glass during installation.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures
> Page 11011
Carefully remove the windshield glass from the vehicle and place on a stable work surface.
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 new windshield glass on the existing urethane bead on the pinch weld.
- Position the windshield glass on the pinch weld.
- Center the windshield glass in the opening.
- Make alignment marks with tape or non-staining grease pencil (preferably at the windshield glass
setting blocks) on the windshield glass and the body.
3. After the dry-fit alignment, remove the glass assembly from the windshield opening and place on
a stable work surface with the interior side of the
glass facing upward.
4. WARNING: Repair any corrosion found on the pinch weld. The pinch weld is a structural
component of the vehicle. Corrosion left
unrepaired may reduce the structural integrity of the vehicle. Failure to follow this instruction may
result in serious injury to vehicle occupant(s).
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 1-2 mm (0.04-0.08 in) base of
original equipment urethane on the pinch weld.
5. Using a clean shop towel, brush or oil-free compressed air, clean the pinch weld area around the
existing urethane. Remove any foreign material or
water that may have entered during windshield removal.
6. If reinstalling the same windshield glass, remove the remaining urethane adhesive from the
glass leaving a thin layer to bond with the new urethane
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.
Clean the inside of the new windshield glass with glass cleaner. Make sure to thoroughly clean the surface of the blackened border area where the urethane
adhesive will be applied.
8. NOTE:
- 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.
- Sika uses the same black primer for the glass and pinch weld area.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures
> Page 11012
If installing a new windshield glass, apply urethane glass primer according to manufacturer's
instructions. Allow at least 6 minutes to dry.
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 continuous bead.
- The windshield glass must be positioned within 10 minutes of applying the urethane adhesive.
Apply a uniform bead of urethane adhesive on top of the existing trimmed urethane bead on the
pinch weld. Make sure that all gaps in the urethane bead are smoothed into one continuous bead.
11. WARNING: Do not drive vehicle until the urethane seal has cured. Follow urethane
manufacturer's curing directions. Inadequate or
incorrect curing of the urethane seal will adversely affect glass retention. Failure to follow these
instructions may result in serious injury to vehicle occupant(s).
CAUTION: Before positioning the windshield glass, open vehicle windows to prevent the air
pressure of closing doors from affecting the adhesive bond.
Using the alignment marks made previously, position the windshield glass on the pinch weld.
12. NOTE: The urethane adhesive must cure for a minimum of one hour before testing for air and
water leaks.
After the urethane adhesive has cured, check for water leaks and add urethane adhesive where
needed.
13. NOTE: Follow the same routing for the electrical connector that was used during removal.
If equipped, connect the heated windshield electrical connectors.
14. Install the cowl panel grille. 15. Raise the front portion of the headliner. 16. Install the interior
mirror. 17. Install the sun visors, retainers and, if equipped, the overhead console. 18. If equipped,
install the roof opening panel trim. 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 (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Locations
View 151-35
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Locations > Page 11018
C4323
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay
> Component Information > Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay
> Component Information > Locations > Page 11022
Wiper Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer
Fluid Level Switch > Component Information > Locations
Washer Fluid Level Switch: Locations
View 151-2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer
Fluid Level Switch > Component Information > Locations > Page 11027
View 151-5
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer
Fluid Level Switch > Component Information > Locations > Page 11028
C138
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations
Windshield Washer Switch: Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Page 11032
View 151-15
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Page 11033
C202
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Testing and Inspection > Multifunction Switch
Windshield Washer Switch: Testing and Inspection Multifunction Switch
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 11036
Windshield Washer Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 11037
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Testing and Inspection > Page 11038
Windshield Washer Switch: Service and Repair
Steering Column Multifunction Switch
NOTE: Steering wheel removed for clarity.
Steering Column Multifunction Switch (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Testing and Inspection > Page 11039
Steering Column Multifunction Switch (Part 2)
Removal and Installation
CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or
damage to the column may result.
1. Disconnect the battery ground cable. 2. Remove the 2 screws and the steering column opening
cover. 3. Remove the 3 screws and the upper and lower steering column shrouds. 4. Disconnect
the multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the
multi-function switch.
^ To install, tighten to 3 Nm (27 lb-inch).
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations
Wiper Switch: Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations > Page 11043
View 151-15
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations > Page 11044
C202
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Testing and Inspection > Multifunction Switch
Wiper Switch: Testing and Inspection Multifunction Switch
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 11047
Wiper Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 11048
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Testing and Inspection > Page 11049
Wiper Switch: Service and Repair
Steering Column Multifunction Switch
NOTE: Steering wheel removed for clarity.
Steering Column Multifunction Switch (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Testing and Inspection > Page 11050
Steering Column Multifunction Switch (Part 2)
Removal and Installation
CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or
damage to the column may result.
1. Disconnect the battery ground cable. 2. Remove the 2 screws and the steering column opening
cover. 3. Remove the 3 screws and the upper and lower steering column shrouds. 4. Disconnect
the multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the
multi-function switch.
^ To install, tighten to 3 Nm (27 lb-inch).
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations
Washer Fluid Level Switch: Locations
View 151-2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations
> Page 11054
View 151-5
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations
> Page 11055
C138
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations >
Two-Way Washer Pump Motor
Windshield Washer Motor: Locations Two-Way Washer Pump Motor
View 151-1
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations >
Two-Way Washer Pump Motor > Page 11060
View 151-4
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations >
Two-Way Washer Pump Motor > Page 11061
Windshield Washer Motor: Locations Washer Pump Motor
View 151-2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations >
Two-Way Washer Pump Motor > Page 11062
View 151-5
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams >
Washer Pump Motor
C137
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams >
Washer Pump Motor > Page 11065
C1397
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service
and Repair
Windshield Washer Pump: Service and Repair
WASHER PUMP
Exploded View
Windshield Wipers
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service
and Repair > Page 11069
Rear Wiper
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service
and Repair > Page 11070
Washer Pump And Reservoir
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the windshield washer pump
electrical connector.
3. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL
INFORMATION seek medical
advice. Failure to follow these instructions may result in serious personal injury.
NOTE: To prevent spilling windshield washer fluid, drain the windshield washer reservoir before
washer pump removal.
Disconnect the windshield washer reservoir hoses.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service
and Repair > Page 11071
4. NOTE: When servicing the windshield washer pump, be careful not to damage the windshield
washer pump seal.
Remove the windshield washer pump.
5. CAUTION: Do not operate the windshield washer pump before filling the windshield washer
reservoir. Failure to do so could result in
premature pump failure.
To install, reverse the removal procedure. Fill the windshield washer reservoir with windshield washer fluid.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service
and Repair
Windshield Washer Reservoir: Service and Repair
WASHER RESERVOIR
Exploded View
Windshield Wipers
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service
and Repair > Page 11075
Rear Wiper
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service
and Repair > Page 11076
Washer Pump And Reservoir
Removal and Installation
1. Remove the air cleaner assembly. 2. With the vehicle in NEUTRAL, position it on a hoist. 3.
Remove the RH front fender splash shield. 4. Disconnect the windshield washer pump electrical
connector.
5. Disconnect the windshield washer solvent level electrical connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service
and Repair > Page 11077
WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL
INFORMATION seek medical advice. Failure to follow these instructions may result in serious
personal injury.
NOTE: If necessary, drain the windshield washer reservoir after removal.
6. Disconnect the windshield washer reservoir hoses.
7. Remove the top bolt.
- To install, tighten to 5 Nm (44 lb-in).
8. Remove the side bolt.
- To install, tighten to 5 Nm (44 lb-in).
9. Remove the bolt.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service
and Repair > Page 11078
- To install, tighten to 5 Nm (44 lb-in).
10. Remove the windshield washer pump reservoir.
11. CAUTION: When servicing the windshield washer pump, be careful not to damage the
windshield washer pump seal.
Transfer components as necessary.
12. CAUTION: Do not operate the washer pump prior to filling the windshield washer reservoir.
Failure to follow these instructions may
result in premature pump failure.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations
Windshield Washer Switch: Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations
> Page 11082
View 151-15
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations
> Page 11083
C202
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing
and Inspection > Multifunction Switch
Windshield Washer Switch: Testing and Inspection Multifunction Switch
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing
and Inspection > Multifunction Switch > Page 11086
Windshield Washer Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing
and Inspection > Multifunction Switch > Page 11087
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing
and Inspection > Page 11088
Windshield Washer Switch: Service and Repair
Steering Column Multifunction Switch
NOTE: Steering wheel removed for clarity.
Steering Column Multifunction Switch (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing
and Inspection > Page 11089
Steering Column Multifunction Switch (Part 2)
Removal and Installation
CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or
damage to the column may result.
1. Disconnect the battery ground cable. 2. Remove the 2 screws and the steering column opening
cover. 3. Remove the 3 screws and the upper and lower steering column shrouds. 4. Disconnect
the multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the
multi-function switch.
^ To install, tighten to 3 Nm (27 lb-inch).
6. To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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. NOTE: Make sure there is no mechanical binding in the linkage preventing the wiper arms from
returning to the fully parked position.
If the distance is not within specification, remove the windshield wiper pivot arm and reposition to
specification.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Exploded View
Windshield Wipers
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair >
Wiper Pivot Arm - Front > Page 11095
Rear Wiper
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair >
Wiper Pivot Arm - Front > Page 11096
Washer Pump And Reservoir
Removal and Installation
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 (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair >
Wiper Pivot Arm - Front > Page 11097
Wiper Arm: Service and Repair Wiper Pivot Arm - Rear
WIPER PIVOT ARM - REAR
Exploded View
Windshield Wipers
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair >
Wiper Pivot Arm - Front > Page 11098
Rear Wiper
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair >
Wiper Pivot Arm - Front > Page 11099
Washer Pump And Reservoir
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair >
Wiper Pivot Arm - Front > Page 11100
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).
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 (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations
View 151-35
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations >
Page 11104
C4323
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations
Wiper Motor: Locations
View 151-2
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Page 11108
View 151-5
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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 differency 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 the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground 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
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 11111
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 parentheses next to or under a component.
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.
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information
Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all fuses and
relays are identified. Fuse and Relay Numbering and Naming. 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.
Power Distribution
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 11112
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.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible.
Component and Connector Information
C904
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
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 11113
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 Component Location Charts.
Component Location Views show the components and their connecting wires as they can be found
on the vehicle.
Locations information that can be found at the vehicle level will help 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 set. 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 lose
clothing.
Symbols
Symbols (Part 1)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 11114
Symbols (Part 2)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 11115
Symbols (Part 3)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 11116
Symbols (Part 4)
Symbols (Part 5)
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 11117
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 terminal by pulling each wire at the end of the connector.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 11118
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 11119
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
3 = Splice tape
4 = Harness tape
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 11120
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.
3. lnstall 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 seat wire splice.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 11121
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.
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 6.35mm (1/4 in) 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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 11122
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.
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, barrel squeeze tool handles appropriate 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 (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 11123
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 11124
C125
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
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
Exploded View
Windshield Wipers
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Wiper Motor - Windshield > Page 11127
Rear Wiper
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Wiper Motor - Windshield > Page 11128
Washer Pump And Reservoir
Removal and Installation
NOTE: A new wiper motor assembly comes with the linkage arm installed.
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Wiper Motor - Windshield > Page 11129
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. CAUTION: Do not remove the wiper motor linkage arm from the wiper motor assembly. If the
arm is removed, the wiper arms may not
park in the correct location.
Separate the wiper motor linkage arm from the wiper mounting arm and pivot shaft assembly. -
Use a suitable tool at the location shown to separate the wiper linkage arm from the wiper
mounting arm and pivot shaft assembly.
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. NOTE: The windshield wiper motor must be cycled to make sure it is in the park position before
installing the wiper pivot arms.
To install, reverse the removal procedure.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Wiper Motor - Windshield > Page 11130
Wiper Motor: Service and Repair Wiper Motor - Rear Window
WIPER MOTOR - REAR WINDOW
Exploded View
Windshield Wipers
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Wiper Motor - Windshield > Page 11131
Rear Wiper
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Wiper Motor - Windshield > Page 11132
Washer Pump And Reservoir
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.
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Wiper Motor - Windshield > Page 11133
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 (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 11137
Wiper Relay: Testing and Inspection
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations
Wiper Switch: Locations
View 151-14
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page
11141
View 151-15
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page
11142
C202
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection
> Multifunction Switch
Wiper Switch: Testing and Inspection Multifunction Switch
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection
> Multifunction Switch > Page 11145
Wiper Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection
> Multifunction Switch > Page 11146
Ford Explorer 2wd Workshop Manual (V8-4.6L (2008))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection
> Page 11147
Wiper Switch: Service and Repair
Steering Column Multifunction Switch
NOTE: Steering wheel removed for clarity.
Steering Column Multifunction Switch (Part 1)